Cardboard Bluetooth Speaker

Creating a cardboard Bluetooth speaker is a fantastic DIY project that combines creativity and technology. Here's a detailed instructable for building a basic Bluetooth speaker using cardboard. Please note that safety precautions should be taken when working with tools, and ensure that the electronics are handled carefully.

Supplies

Electronics:

1. Bluetooth Audio Module: Choose a Bluetooth module that includes an amplifier, such as the PAM8403 or similar.
2. Speaker Drivers: Two small speakers (usually 3-4 ohms) for stereo sound.
3. Battery: A rechargeable lithium-ion battery with a capacity suitable for your usage.
4. Battery Charging Module: A charging module suitable for your battery type.
5. Switch: A small toggle switch for turning the speaker on/off.
6. Wires: Assorted jumper wires for connecting components.
7. Bluetooth Antenna: Optional for better Bluetooth signal range.

Structural Components:

1. Cardboard Sheets: Sturdy cardboard sheets for creating the body of the speaker.
2. Wooden Dowels or Skewers: For additional structural support.
3. Wood Glue: To attach wooden supports to the cardboard.
4. Hot Glue Gun: For attaching electronic components and reinforcing joints.

Tools:

1. Utility Knife or Box Cutter: For cutting cardboard sheets.
2. Ruler or Measuring Tape: For accurate measurements.
3. Wire Stripper: For stripping wire insulation.
4. Soldering Iron and Solder: For connecting wires and components.
5. Drill with Bits: For making holes in cardboard.
6. Sandpaper: For smoothing edges.
7. Paints and Brushes: For decorating (optional).
8. Bluetooth Speaker Grill (Optional): To protect the speakers.

Step 1: Design the Speaker Body:

Measurements:

• Cut the cardboard into panels for the front, back, sides, and top of the speaker.
• Design a rectangular box that accommodates your chosen speaker drivers and electronics.

Step 2: Assemble the Structure:

Cardboard Box:

• Use wood glue to attach the cardboard panels, forming the box structure.
• Reinforce corners with additional cardboard or wooden dowels.
• Let the glue dry completely.

Step 3: Install the Speaker Drivers:

Placement:

• Cut holes in the front panel for the speakers.
• Attach the speakers using hot glue or screws.
• Optionally, attach a speaker grill for protection.

Step 4: Mount Electronics:

• Bluetooth Module:
• Find a suitable location for the Bluetooth module.
• Connect it to the speaker drivers and battery using jumper wires.
• Battery and Charging Module:
• Place the rechargeable battery inside the box.
• Connect the battery to the charging module and the Bluetooth module.
• Switch:
• Install the on/off switch in a convenient location on the speaker box.

Step 5: Wiring:

Jumper Wires:

• Use jumper wires to connect the components, ensuring a clean and organized layout.
• Solder connections for added stability.

Step 6: Secure Components:

Hot Glue:

• Use hot glue to secure the electronic components in place.
• Ensure there are no loose wires that could interfere with the speaker's functionality

Step 7: Test and Fine-Tune:

• Bluetooth Connection:
• Pair your device with the Bluetooth speaker and test the audio.
• Sound Quality:
• Fine-tune the placement of the speakers for optimal sound quality.