Hi All,
I have a plasma TV, which has decent sound quality 15W, but with kids making noise, it is difficult to listen...

I needed a sound bar to amplify my TV's sound level with digital-optical audio in. but only available in high end and expensive sound bars

The entry level soundbar have just 15W output, which is too less for my requirement

Inspiration came from my dad, he had few old Car speakers (20W) lying around, which he wanted to throw. So thought to use them and make a sound bar for myself

In this instructable, will share how i made it, Please share your comments

Features

100W output (90db)
180w coaxial speakers with tweeters
Bluetooth 4.0
Fibre audio / coaxial in
RCA audio in
USB 5 volts regulated power for charging phone while playing
Button controls
Bass tubes
Strong plywood frame
Equaliser graphics is just for show

Step 1: Design

I am using TDA7492 class D 50W+50W amplifier with built in bluetooth 4.0 and Aux in.
The Amplifier is powered using old laptop charger.
OUtput connecter to 2 speakers
Aux is connected to RCA audio ( to be mounted on rear side) in via 3.5MM stereo
To this RCA Audio I will connect my Optical audio to Analog converter
To power Digital to Analog convertor, I am using LM2596 to step down to 5V
Also using a USB type 2.0 as 5V out, This can be used to charge mobile phone during bluetooth playtime

Step 2: What Do We Need ?

Material

15 mm plywood
6 mm plywood
wooden dowel
TDA7492 50+50W/ Bluetooth 4.0, Aux In CLass D amp
Bluepunkt IC 402 180W Coaxial speakers with tweeters
Old laptop charger
3.5 mm audio cable
RCA female connector for surface mount
Usb female type 2.0 for surface mount
Switch
LM2576 DC - DC step down 3A ( Adjusted to 5V)
Optical audio to Analogy converter
RCA audio cable

Tools

wood saw
Dremel with 2mm drill bit
Hammer
screws
fevicol
glue gun
Cable tie
black oil paint
Sand paper

Step 3: The Frame

To make the frame cut 15 mm plywood

431.8 mm x 114.3 mm - 2 pieces
95.2 mm x 114.3 mm - 2 pieces

Front panel and back panel is 6mm Ply wood

114.3 mm x 431.8 mm - 2 pieces

Use the template supplied by manufacturer to drill/ cut out a hole to fit speakers. I used dremel to drill holes and then chisel to cut. To smoothen the hole I used 80 grit sandpaper

Glue all sides and front panel using PVA glue or fevicol, leave it overnight to dry. Remember to seal all gaps using glue and saw dust.

Add wooden strips (5mm) on the back side that will hold the back panel.

Using Sandpaper 80, 150 then 220 grit, smoothen the surface and paint it based on your choice. I used black oil paint, this gives shine to the frame...