Tin Box Speaker

This is a project I've been wanting to do for a long time. I wanted to use a Kenwood speaker and make an external speaker box for my Kenwood amateur radio. I've just been waiting for the right box to turn up. Ideally I would have liked to use an old saltine's cracker tin, but those are both rare and valuable. So I decided that if I ever came up with a tin the right size minimums that I would build the speaker. This Instructable is meant to show you how to build the tools you need when you can't buy them in a store. It is also a chance to see how to use an air nibbler. This is a device that cuts small shards of metal at a high rate of speed and requires FULL safety protection. This is a tools that is powered by an strong air compressor and should only be used with the supervision of an adult. Children, get your parents permission and help when using ANY tools.

This instructable is entered into the Craftsman Contest so please vote it up, Thank you.

Step 1: Parts Needed

Parts need for this project are:

Speaker - KENWOOD 4" Full Range
Holiday Styled Tin 4"x4"x6"
Plastic Baskett - Pool filter
Foam Packing Material

You will also need an assortment of fastening hardware and rubber feet and other household stuff.

Step 2: Tools

In general, you will need a drill with assorted bits and drivers. A measuring device. A nibbler, I chose to use an air powered nibbler and suggest that you use a hand operated nibbler. You will also need to have a roll of tape, sewing needle and other assorted household stuff.

Step 3: Measuring & Marking

Start by marking the mounting holes. This is easy to do using a marker because the 4" speaker fits perfectly into the 4" tin.

Next measure the diameter of the speaker hole. For my speaker it is approx. 3 3/4".

Transfers that measurement to a roll of tape.

At the Diameter location on the tape roll insert a sewing needle.
(Use a thimble or other hard metal to push the needle in SLOWLY) The needle can be easily removed with pliers.

You are making a scratch awl for circles.

Place the roll, needle side down, onto the tin and give it a few full turns.

You now have a perfect circle scratched into the surface of the tin. This is your cut line.

Step 4: Cut & Drill

Drill a pilot hole for the nibbler in the center of the tin. For my nibbler I needed a 1/2 " drill bit. Also drill the pilot holes for the speaker mounts.

Insert the nibbler and carefully cut along the scratch line. CAUTION!!!! If you are using an air nibbler you will be creating a shower of metal shards. They get everywhere and are quite painful if stepped on.

Cut off the base of the pool strainer basket. Enlarge the holes with a drill if you desire to. Drill the speaker mount holes using the speaker as a template.

Step 5: Coatings & Assembly

After a liberal coating of flat black spray paint, the speaker box is ready for final assembly. At this time you can choose to add and audio amplifier to boost signal to the speaker, but for my needs I'll just connect it straight through.

Mount the speaker grill so that it does not interfere with the operation of the speaker. I used 1/4" spacers.

Mount the speaker and grill with some small machine bolts.

Insert the packing material into the box. Add some rubber feet to the bottom.

Done.

This speaker not only looks great by itself but looks and functions great with the Kenwood Amateur Radio.