DIY Tough Bluetooth Boombox (Lasts 20hrs!)
Intro: DIY Tough Bluetooth Boombox (Lasts 20hrs!)
Get ready to build a tough & rugged boombox! "RaveBOX (v1.0)" can charge USB devices, play MP3s and tune to FM stations! It also comes with an IR remote offering better convenience. The boombox gives action sports and outdoor enthusiasts 18 hours of nonstop music. Whether you're at the beach, shooting rapids, or hiking outdoors, the boombox remains safe in its tough (Pelican-like) weatherproof shell.
How I Came Up With The Design:
It's been a while since I last posted my last boombox tutorial, it was pretty much a success but as we all know technology advances annually. RaveBOX is now as powerful as my old boombox but it's half the size of the old one.
I really had no design when I made this project, I had a "go with the flow" sort of vibe. One day I went to the mall to buy my usual supplies then suddenly I came across this generic Pelican-like case. They were selling it for like P480 ($9.60), I still had some speaker lying around, so I thought it would be cool to fit my four unused fullrange speakers + my 4" HiFi woofer. With no hesitation, I bought the awesome looking case. As I went back home, I started searching for parts in my inventory. I still had some amp chips lying around. I found two extra 2x3 Amp Modules (form dx.com) and my beloved Bluetooth Player Module (from dx.com).
All that's left is my battery, I wanted to make sure that my boombox would last a day of non-stop playback without charging, so I though of a solution! My robots are using LiPo batteries since they had a high "size to power" ratio, meaning they have a high mAh rating for their extremely compact size. Since the competition is still scheduled for December, I borrowed some of my LiPo batteries and decided to put them in my new speaker project.
Specs/ Features:
- 2.1 Channel Audio System (6W + 6W + 20W)
- USB Charging Capabilities (6600mAh)
- 18hrs Max Playback (LiPo Bat)
- Bluetooth 3.0 Audio Connection
- 3.5 Stereo Auxiliary Connection
- Equipped w/ FM Radio Tuner
- IR Remote Control
WARNING! You'll need some basic soldering skills, a little knowledge of electronics, and some patience to build this. Please don't blame me if you mess up the modules. SMD chips are very sensitive to over-voltage, handle them with extreme care! There's a lot to go wrong with this project. Good luck!
STEP 1: Tools & Materials
- Bluetooth/ FM/ USB/ SD Player Module (w/ Remote)
- 2-Channel 3W PAM8403 Audio Amplifier (2pcs)
- Generic Watertight Container (Pelican Knockoff)
- 3 Cell 2.2A Lithium Polymer Battery (Turningy)
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Speaker Alternatives:
- 3W Fullrange Speakers (4pcs) [Alternative#1]
- 3W Fullrange Speakers (4pcs) [Alternative#2]
- 4" Woofer Speaker (8 ohms) [Alternative#1]
- 4" Woofer Speaker (4 ohms) [Alternative#2]
- 4" Woofer Speaker (8 ohms) [Alternative#3]
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TDA2005 Amplifier Parts:
Capacitors (25V)Resistors (¼w)MISC. 220uF (2x) 120K TDA2005 I.C. 100uF (2x) 2K Screw Posts 2.2uF (2x) 1K 100kΩ Pot 100nF (3x) 12Ω (2x) Heatsink 10uF (1x) 1Ω (2x) ______________________________________________________
Tools, Materials & Equipment:
- Rotary Tool (Dremel)
- Leatherman Multitool
- Portable Electric Drill
- Silicone Applicator
- 40W Soldering Iron
- Mini Hot Glue Gun
- Electrical Tape
STEP 2: Measuring & Marking
STEP 3: Drilling & Cutting
STEP 4: Clean the Edges
STEP 5: Mounting the Speakers & Bluetooth Panel
2nd.) Seal the woofer's gap with a bottle of silicone sealant.
3rd.) Use superglue to mount the four tiny full-ranged speakers.
STEP 6: Wiring Instructions
Notes:
- The Bluetooth module/ panel has an internal regulator (5-30v)
- Do not ground the speaker, they have separate lines
- They all share a common ground (negative wire)
- The PAM8403 amp module's "SW" pin is N/C
- Keep the wires as short a possible
- Observe proper speaker polarity!
- Use thick wires for the mains
STEP 7: Installing the Full-range Speaker's Amplifiers
STEP 8: Finding a Good 5v Regulator
1st.) Disasseble the cheap 12v USB charger
2nd.) Get the charger's circuit
3rd.) Disolder the USB's female plug.
4th.) Solder both PAM8403 amp module's 5v-input parallel to the 12v USB charger's 5v output.
STEP 9: Mono Amp PCB Fabrication
Learn To Fabricate PCBs:Click Here (Visit My Other Tutorial)
STEP 10: Assembling the Mono Amp
Sorry! I forgot to flip my PCBs image, so I did the wrong side soldering method to get the pins right. Don't wory about the downloadable content, it's been corrected. If you are still confused, base the orientation on the schematic diagram.
STEP 11: Combining L + R Channels for the Woofer
The L-Channel, as shown in the diagram, goes to your Bluetooth module's left audio out. While the R-channel goes to the right. The M on the other hand goes to your woofer's amp (audio-input).
STEP 12: Choosing & Installing the Battery
Remember, Lithium batteries don't like to get themselves drained for a long time, if they do, they bloat. And don't forget, they need special chargers, the ones with configurable LCD screens. Be careful with them and don't forget to do a monthly check on the battery!
222 Comments
ynze 10 years ago
You put the charging unit directly to the lipo battery. So you can charge only 12V devices? What's the idea behind that? It would be cool to put a voltage regulator in between, so you can charge phones, psp's and mp3-players...
ASCAS 10 years ago
The charging plug is for the boombox's LiPo charger. If you look at the boombox very closely, the Bluetooth panel has a USB port. You can certainly charge any type of USB device (iPhones, PSPs, etc...).
tiagos 9 years ago
So for the pcb amplifier ?
jmrittenhouse77 8 months ago
rizzle733 10 months ago
Why is that done? Is it a mid pass filter .. or?
unico1 4 years ago
altonv1 5 years ago
altonv1 5 years ago
JETHROGREEN7373 5 years ago
Megadrive 5 years ago
PatrickT4 5 years ago
Is there a way to integrate charging into this unit so the battery doesn't need to be removed for charging? Maybe using a portable power bank or alike?
dylanclark9521 6 years ago
KishoreK67 6 years ago
I have started doing Bluetooth DIY speaker. I am using the following Equipment
1. 15w 2 channel amplifier board
2. Bluetooth module the one which you have used.
3. 3no. 18650 battery (12.6 voltage connected in series)
The problem is that I am getting a Humming noise when I connect the Signal output of Bluetooth module (Rout - GND - Lout) to the input of the Amplifier board.
I tried connecting all the GND to battery GND. but still the noise is present.
Is there any way to rectify the problem
Joshua Marc Perry 6 years ago
Do you need a Li-Po battery charger or can you use a a DC power supply connected to the mains?
MarkM611 6 years ago
Just wondering what value of
capacitor you used here and what difference it made? I’ve search the web and
haven’t been able to find any information on it.
Spark85 7 years ago
JesseE23 7 years ago
I was just wondering where did you go to get all the components to build the mono amplifier. I would like to just buy all of them at one location or one website.
Thanks
Alex345 7 years ago
what kind of gauge wire did you use.Or what kind of wire should I use
DavidB952 7 years ago
Hi! Nice project.
How did you come up with the 18 hours of nonstop music?
with the 2200 mAh LiPo battery at 11.1 V and 32 W maximum power drawn by the amplifier, your battery would last much less in theory. Is this at full volume? What is the current drawn by your system at full volume? Thanks
pkocurek 7 years ago
Hey, I really like this instructable. I would love to make the box, but I'm being lost with drivers. In your text, you say 20w, but on your woofer, there is 150w. Will the speakers you recommended work with listed amps? thanks