Introduction: JBL Speaker Container

You could use ear buds to listen to your favorite music. But wearing a helmet and ear buds is not an ideal combination (my opinion though). My motorcycle is a sort of naked bike. So I can't use fairing speakers. Instead I want to use my JBL Bluetooth speaker (dimensions w x h x d : 175 mm x 74 mm x 74 mm).

The idea is to build a container for the speaker which I a can mount on the handlebar (diameter 25,5 mm). I first created some sketches on paper.

Step 1: Prototype JBL Speaker Container

After I had an idea of how it should look like, I made a simple prototype.

The next step is to make a 2d of 3d design of the container (Sketchup or 123 design). I have never used these programs. So I think it will take me some hours to learn how to use these programs. I can't do it without these programs, because I want to use a 3D printer and a laser cutter to make a better model.

Step 2: 3D-design

Well, the first parts are done. I used 123 design. Pretty easy to use and tons of vids on youtube to help you out.

The part on the left of the picture has been printed at Stadslab Rotterdam. The 3D-printer needed lots of time, because I wanted to print a pretty solid piece.

Unfortunately the printer had a failure halfway (see pictures). So this plan is not working for the moment.

I have decided to use the laser cutter instead of the 3D-printer. Back to the drawing table.

Step 3: 2D-design

Luckily Adobe Illustrator CC was able to convert the dxf files of 123 design. Although all lines had to be adjusted in the right thickness (0,01 mm = 0,028 pt) and color (RGB 255, 0 , 0 ). Jerry, steward at Stadslab Rotterdam, helped me a lot. So I owe him many thanks.

I have uploaded the ai-files, but I'm not sure if you can open them.

I used 6 mm birch plywood. The lasser cutter had to cut the plywood up to 4 times in order to release the pieces.

The next step is to glue the plywood pieces together.

Step 4: Assembly of the Plywood Parts

The laser cutter has cut 31 parts. I started with the assembly of the parts which will hold the container on the handle bar. I used assembly wood glue .

After that I assembled the parts for the container. Again I used assembly wood glue and drilled holes for the hinge points. The upper part must be able to move up and down.

I used dowels for the lowest part, because that part has to be firmly and not movable.

To combine the assembled parts I used bolts and nuts. The plywood strips are mounted with little screws.

Step 5: Installing Leds and Connector Cable

Given that the JBL container will be mounted on the handle bar of my motorcycle, I will not have visibility on my control panel (turn signal indicator (orange), neutral indicator (green), oil pressure indicator (red) and high beam indicator (blue)).

In order to solve this little "problem" I decided to install 4 leds (12 volt) in a square metal housing. I used heat shrink tubing to protect all of these thin wires. The wires are connected with a male connector and will be connected with a female connector which is connected with the wiring of the control panel.

The extended control planel is attached on the bottom lath.

I tested the leds on a 9 volt battery and it worked.

The next step is to mount the JBL container on the handle bar and make a test ride. YEAH!

Step 6:

This is the final result. The JBL speaker container is mounted on the handle bar. It fits well and it's attached firmly. It's freezing cold outside. So, no test drive today. Gosh, I miss the summer.