Boomcase Mimic

Hey everyone.  I just wanted to share my version of the popular Boomcase.  I didn't want to drop over 500 dollars for one so I made my own.  Materials cost me about 50 bucks, and labor was two weeks, mainly waiting for parts to arrive. Majority of the items are reused from a thrift store or I harnessed it from old electronics.   It's still a work in progress since I am still working up a way to add a battery and charging option to it.  Happy Viewing!!!

Step 1: Parts and Tools List

Parts:
Lepai 2020A+ Amplifier
1960 American Tourista Tiara suitcase
2 used panasonic 4ohm, 3watt, 6 inch speakers
2 used RCA 1.3 ohm, 1.5watt, 5 inch speakers
1 philmore DC panel mount jack
1 3.5mm panel mount jack
1 retractable 3.5mm male to male audio jack

Tools:
12v-18v drill
1/2" Drill bit
1/4" Drill bit
hand saw or in my case a stainless steel kitchen knife ( router is faster)
solder, soldering iron
electrical tape
voltmeter
Dremel, sanding bits
Plastic masking
3M or similar masking tape
pencil
ruler

MR BARTENDER APP  LOVE IT. 

ANDROID:   https://play.google.com/store/apps/details?id=com.LEO.Mr_Bartender&hl=en
APPLE:   https://itunes.apple.com/ag/app/mr-bartender-mixed-drink-bartending/id505867992?mt=8

Step 2: Step1

-Figure out what your desired speaker configuration should be.
-Do a mockup in a cardboard box, mine was from a item i just ordered that week.

Step 3: Step2

-Tape up your suitcase, draw your template
-Drill starting holes, and cut into the box, a router would be ideal but I only had a stainless steel kitchen knife from one of those infomercials my mom got me, I never had the need to cut through a frozen turkey or bricks with it.   
-Dremel your holes smooth and to fit the speakers.

Step 4: Step3

-Drill holes to fit amp, dc jack and 3.5mm jack.
-Fit everything and wire it all up, tape it all up, your DC plug and 3.5mm, use the volt meter to find the positive and negative of the DC plug, usually striped wiring or red is positive.
-hot glue everything to case.


-Note: the amp has only 2 outputs at 8 ohms each, if you want to add tweeters you would need crossovers or component speakers that have built in crossovers which mine did. 

Step 5: Step5

-Close it up, plug it up and enjoy

Happy DIYing!........

Step 6: Battery

For now I'm using my portable 10,000 mah Anker battery that I use for charging any 5v usb or 9v/12v dc electronics on the go.  It can power the case for over 10 hours at the volume and amp draw I play it at.  And when not in use i pull the bat out and use it for my cellphones, cames in handy during hurricanes like Sandy. 

Step 7: Speaker Sound Test So Far.....

Here is what it sounds like so far.... 

http://www.youtube.com/watch?v=adbMQEZHQEg&feature=youtu.be

Comments

[jm31181]

Battery section update.

[nerdologist]

I know that this instructable is like 12 internet years old but I'm hoping that you see this question. How did you get the battery to run the amp? I purchased the same amp, battery and only one set of speakers (smaller speakers, too). When I hook the battery up to the amp it powers up but it won't power the speakers. Then I turn off the amp and hook it up to the wall outlet and it powers everything just fine. Thank you for the great instructable!

[nerdologist]

Nevermind. I figured it out.

[Scott Nonsense]

I'm having the same problem - how did you figure it out?

[AbsoluteB1]

how did you connect the battery in the end?

[SpencerK2]

How did you figure this issue out? I have having the same problem. Thanks!

[jm31181]

Thanks for all your suggestions, I am still finding a charging solution and I'll def look into speaker covers and barrier/ fill separators for it. Love all the ideas!

[QuentinK6]

So I am hoping people are still following this thread: I am interested in doing a boomcase, but really unsure about the power requirements. What I intend to do is mount up to 6 speakers, as well as an aftermarket 1-din head unit from Sony, Alpine etc. so that I can use the bluetooth and/or disc drive for tunes: I may also require a powered amp in order to handle the multiple speakers. The thought is that the boomcase would be plugged in to a standard wall socket, but because I want to use an automobile stereo, that I should require a converter?? I found a 12 Amp Variable Linear Regulated Home Lab Benchtop AC-DC Power Converter; would this put me on the right path? looking forward to any comments :D

[qwertydude]

You know if you're looking for a good charger battery solution, I find the best for my boombox projects is a 3 cell 5000 mah li-ion RC car pack. This will offer plenty of power and adds very little weight unlike the more popular lead acid setup I always see.

Plus these also have a balance jack that can be used for a charger. So my setup uses a 3 cell lithium balance charger and 3 cell lithium battery. What's really nice is the charger automatically charges the battery and can even do so while you're using it. Plus it takes either the supplied adapter or you can make a car adapter so it can charge in your car too.

And the best part is the price. You can get the charger and battery usually for less than $40 online.

[TomW49]

Is that 3 seperate batteries or a battery with 3 cells?

[Tater Zoid]

Thank you for the battery info. I'm trying to charge and play my boombox without opening my case.

[jm31181]

Do you have this battery in a firebag? One thing i've heard of charging lithiums is that overcharging will set them on fire.

[qwertydude]

Well then don't over charge them. I've measured the charger when it charges, mine shuts off charging at 4.18 volts so there's not danger of overcharging. I have never had one overcharge for the 4 years I've been using lipo.

I have had some cheap chargers that came with some RC helicopters that did charge to 4.21 volts still under the 4.25 volt threshold but I threw those away. But basically if you're not an idiot with charging you'll be safe.

There's always a danger with a hydrogen explosion with lead acid because of charging in an enclosed area, but how paranoid are people of that risk?

[joshvonnieda]

do you have a link for this battery and charger? i'd like to upgrade my setup.

[qwertydude]

No real link because supplies are always changing.

But ebay is a great place to search. Look for these two items. Be sure to filter US only so it doesn't take a month to get your equipment. Here are some pre filtered links to look through.

http://www.ebay.com/sch/i.html?_sop=15&_from=R40&_sacat=0&_nkw=3s+5000+mah+lipo&LH_PrefLoc=1&rt=nc&LH_BIN=1

And for the charger.

http://www.ebay.com/itm/Balancer-Charger-Balancer-For-7-4-11-V-2-3S-Cells-RC-Li-PO-lithium-AEG-Battery-/271054525554?pt=Battery_Chargers&hash=item3f1c1bd472

This doesn't come with an adapter to plug into the wall but a simple 12 volt adapter that fits the socket works just fine. You can also make one that plugs into a cigarette socket in a car.

[rcarswell2]

Finished up a drum case speakerbox for my wife this Christmas. It was her old snare drum case from high school. I found Pyle waterproof speakers on Amazon for $15/pair and they had built in louvre covers that had a nice retro look to them. I got the same Lepai 20W amp and picked up the Anker battery too. It all works amazingly well. I fabricated some wire extensions to connect the amp to external jacks (3.5mm stereo jack, RCA plugs and an external AC adapter jack). And then cleaned it all up with flexible wiring loom (think chinese finger trap). I also added a drawer pull to the front just above the amp's knobs to protect them from getting banged up. [**trying to post photos here in this thread, but instructables is being difficult.**]

[pcanning1]

How are you wiring up the 4 speakers to the amp (as it is only 2 channel?)

[rcarswell2]

I wanted 4 speakers on this sized case and I realize the amp is only two channel, but the amp also has output for two sets of speakers. Presumably for front and rear like in a vehicle, but it lacks fade controls. So I just utilized all 4 speaker connections on the amp 2 Left, 2 Right. I'm sure by plugging in 4 speakers I'm reducing the wattage to each channel, but I'm happy with the look of 4 speakers and the overall sound and loudness.

[seattler]

Great job! How did you mount the the Lepai...it looks like you took the faceplate off of the front and opened the unit up, is that right? I'm trying to figure out how to cut an opening in my suitcase and secure the amp without it looking like a hack job.

[jm31181]

What I did was remove it from the casing with 2 screws on the back and 4 in front where the faceplate it. Than you can get an idea of what your working with. Cut a rectangular area that is enough for the amp board to fit through but not past where the faceplate screws would go. You can use the casing as a template. Just keep cutting and test fitting. I would cut a little at a time because once you cut too far you will not be able to install the entire unit onto the case. Once you have enough cut and the board fits into the case you can drill holes where the faceplate original screw hole were and screw into the case. Hope this helps.