Step 1: Materials
Styrofoam Plate - Better resonance is the reason for choosing styrofoam, paper and plastic plates have a much duller sound. But feel free to play around with different types of materials.
Construction Paper - This is used as the coil and also to "mount" the speaker. I had previously used printer paper but found it wasn't sturdy enough for my liking.
Styrofoam Square - I just cut this out of an old styrofoam presentation board, it is used as the stand or base of the speaker. Material is not of high importance here just make sure it is sturdy as this will be supporting the entire structure, including the magnet.
Scissors - Used for cutting and shaping construction paper. Make sure you use sharp scissors to make your cuts perfect as it will directly effect the balance of your speaker (which directly effects the loudness of your speaker).
Wire - This is crucial guys! Make sure you get 32 awg enameled wire, 30 awg will not work as easily (I will explain later). The best place to get this is Ebay in my opinion because I ordered 300 feet for 5$ (free shipping). This is used as the coil.
Magnet - Again this is very important also. The strength of the magnet you choose will decipher the loudness of your speaker. I find it is much easier to use a circular magnet for this project because I can't even imagine trying to build a square voice coil. Again Ebay is the best place for magnets, I always use neodymium magnets as they are the strongest available. The magnet I choose was 20$ and has a pull force of 150lbs. So please be very careful with these magnets if you choose to use them, they will destroy or computer or laptop with no problem, and can also break fingers very easily.
Super Glue - The most useful resource on the planet. I use super glue when I don't want to wait for Elmers glue to dry but with much patience it will work just as well. Although with super glue one mistake probably means you have start over again from the beginning as it eats through Styrofoam like acid.
Elmers glue - For this entire project I am going to highly recommend using this because it just turns out much better. Remember patience is virtue.
3.5mm Jack - This is how we are going to send the speaker music. Find an old pair of headphones and strip the leads down. Also if they look greenish or redish after you strip off the plastic it may also be enameled. If that is the case you will have to find some light sandpaper or a lighter and make sure you have bare metal exposed on both leads. The one I choose was actually from an old speaker of speakers and was a Tri-conductor.
Step 2: Step 1 - Find the Center of Your Mount.[IMG]http://i249.photobucket.com/albums/gg210/Frankanthony1/Center.jpg[/IMG]
Take a ruler and draw a line from corner to corner on your styrofoam square forming an X and you should have your perfect center, super simple!
Step 3: Find the Center of the Bottom of Your Plate
Step 4: Cut Out Your Voice Coil Base.
Step 5: Place Your Magnet
Step 6: Trace the Circle.
Step 7: Assemble the Voice Coil Base.
Step 8: Glue the Voice Coil Base and Magnet Into Place
Make it stick
Step 9: Wrap the Coil.
Step 10: Build Your Spider!
Step 11: Form Your Spider.
Step 12: Mount the Spider.
Step 13: Connect the Wires.
Step 14: Wrap Up and Video.
Heres another video http://s249.photobucket.com/albums/gg210/Frankanthony1/?action=view¤t=speaker.mp4