The following project will show you how to take 3D Solidwork's renderings and 2D Illustrator files and create a minimalist iPhone boombox. The boombox is my design and creation. Originally for a production class, I designed and created the boombox in an attempt to design, render and create using computer programs. Other goals of the object were to hide witness marks and create a minimalist and retro design. Please feel free to contact me with questions or with photos of the boombox you create using my Instructable, especially if you use different materials or components.

If you like the design and the way I took the idea from computer to reality please vote for me in the Make It Real competition!

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This Instructable is for the the Make It Real competition. Thanks to the judges for giving me the opportunity to continue design. Winning a 3D printer while still in school would allow me to do incredible thing like rapid prototyping, form studies and so much more.

Thank you for viewing and voting!

BoomBox.PDF
Download

Step 1: Step 1: Materials

Materials:

1/2 inch MDF (Board Atleast 14 x 12)
1/4 inch MDF (Board Atleast 14 x 12)
1/4 inch Clear Acrylic
5/8 inch Dowel

1/2 inch Cloth Elastic Band

Mini Rocker Switch
5mm LED
AAA Battery Pack
Altec Lansing IMT227 OrbitM Speaker
Electrical Wire
1/4w 62 OHM Resister

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Where to Purchase the Speaker:

http://www.amazon.com/Altec-Lansing-Technologies-IMT227-Portable/dp/B006KZ0R1Q/ref=sr_1_1?ie=UTF8&qid=1329438061&sr=8-1

Step 2: Step 2: Tools

Tools:

Laser Cutter
CNC Router
Soldering Iron
Hand Router
5/8 inch Drill Bit
Wire Cutters

Step 3: Step 3: Cut MDF

Download the 3D Solidwork's files that I have uploaded. Send the files to a CNC Router. Cut out front and back panels. Cutting out extra's will allow room for error or the opportunity to make multiples.

This is your chance to experiment with other materials, I'd love to see some of these in fine woods!

Step 4: Step 4: Cut Acrylic and MDF

Download the Adobe Illustrator files I have uploaded. Using a laser cutter, cut out the acrylic middle insert and the two 1/4 inch MDF inserts.

Step 5: Step 5: Cut Dowels, Dowel Holes and Speaker Well

Line up the acrylic middle so that you can drill holes into the MDF for pegs. Drill 4 holes on each MDF panel. Be as accurate as possible so that the panels line up correctly. Cut your dowel into 1/2 inch pegs that will fit into the holes. Fit panels together so that you can use a hand router to cutout a well into the back panel for additional speaker space.

Step 6: Step 6: Finalize MDF Insert

Finalize the MDF insert by wrapping your cloth elastic band over the cutout and using a small amount of epoxy on the sides.

Step 7: Step 7: Wire Speaker and Lights

Begin to take apart your Altec Lansing speaker. Be very careful during this step, this is the life of your object and you don't want to end up buying more than you need like I did. You will be discarding most of the casing but be careful as you remove the faceplate. Additional screws can be accessed through the bottom of the speaker. You will most likely need a hex key and a small screwdriver. DO NOT LET THE AUXILIARY WIRE GET CUT. Be carefull when getting the speaker out!

Included in the images is the part of the case you will need as well as what the speaker looks like. You will be wiring in parallel so that all components receive equal amounts of power. Below is website for learning how to wire in parallel.

http://www.termpro.com/asp/pubs.asp?ID=124

Be sure to wire slowly and have a good understanding of how to do it before you start to solder everything. TEST, it's important. I didn't know anything about how to wire the parts together so i started by setting up one LED light, then adding a switch, then more LED lights and eventually the speaker.

Step 8: Step 8: Sand, Glue and Stain (Optional)

Depending on the CNC router you used and how careful you were during construction you may need to do some finishing work on your speaker. I painted the speaker cap white for a nice plain detail. You can further protect your MDF panels by taking them off and coating them with a clear staining agent. If you used a wood besides MDF then play around with other stains and protective agents.

You are also going to want to glue the speaker to it's cap from the inside and glue the speaker plate to the bottom panel of MDF. This will secure your speaker and reduce rattling.

While the pegs hold the panels together nicely you may want to use a little glue and clamp the panels together over night. You wont have access to the inside anymore so make sure everything is strongly secured, wired and soldered inside if you do this!