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Sony PSP audio docking station

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Step 11: Speaker cover

Picture of Speaker cover
cover7web.jpg
I designed a speaker cover with a shape similar to the PSP. As raw material, I choose a transparent empty chocolate box. Eh! Eh! If you love DIY, do not throw away this smart, useful material! It is polystyrene (PS); transparent but fragile.

I cut the panel off the box using a hand modelling saw. It is very difficult to use electric tools with this plastic, because the blade warms up during sawing and melts the plastic.
After cutting the covering panel, I put it in place and marked the position of the speakers and of the outer screws. To allow sound to pass through, I drilled a dense grid of small holes (2.5 mm diameter). For this delicate drilling, I used an electric screwdriver, because the rotary tool turns too fast, even at the lower speed, and melts the plastic. The screwdriver is OK, but very slow, therefore drilling all the holes took almost two hours!

At this point I got a transparent cover (picture 4). I painted the back side with silver acrylic paint. The front side keeps the glossy plastic surface, perfect without painting. The cover was mounted with the four outer most screws of the speakers. I made some small cylindrical spacers to be separate the speakers from the cover.
he back side with silver acrilic paint. The front side keeps the glossy plastic surface, perfect without painting. The cover was mounted with the four outer most screws of the speakers. I made some small cilindric spacers to be separate the speakers from the cover.
 
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