I started this project after seeing ASCAS's DIY Tough Bluetooth Boombox project. I liked the idea of a homemade speaker. I didn't however want such a big speaker. Instead I used his component list to get some of the parts while not using most of them. Their boombox had 5 speakers in it while mine had 2 that I salvaged from an old TV. When I first started this I designed a housing with the speakers on either side. At this point I stopped my project because I was waiting for my components to arrive from China. When I finally got them I decided to redesign the casing to have both speakers facing forward.
Step 1: Components
Some of the main components I used were from Deal Extreme while others like the battery, speakers, and 5v regulator weren't. For the speakers I couldn't find an identical pair online but I found some sony speakers with the similar dimensions. I got the battery off amazon. Plan your project as shipping takes a long time.
These are the main electric components but you also need a switch to turn it on and off and a DC charger jack and cable. The DC charger jacks can be ordered from almost any site varying in price where you can get 300 for 5 dollars or 1 for 7 dollars so you can chose whatever you want. The switch should be a rocker switch and these can be found everywhere.
Other components I used were some nuts and bolts to screw the speaker in and a lot of heat shrink tubing
Step 2: Tools
All that you need is a soldering iron to connect the components, glue to secure them in the case, sand paper to smooth your 3d prints, a screw driver to attach your speakers and a 3D printer to make the enclosure.
Step 3: Assembly
The assembly is easy but requires a lot of soldering. The first step is to solder wires on the amplifier chip. Then screw on the speaker. Once they are connected you can solder the speakers onto the amplifier chip. Then connect the ground and 5 volt wires on the chip onto the 12v to 5v regulator. Then connect the left output to the chip. Now start with the battery strip the wire and connector off of the positive pin. Connect a wire to the dc charger jack and one to the rocker switch. Now connect the output from the switch to the 12v side of the regulator and the bluetooth module. Next strip the ground off the battery and connect it to the 12v regulator, the bluetooth module and the dc charger jack. These are the files I used.
Step 4: Finishing It Off
Now just glue the battery, and regulator in the case and screw in the module. Put all the wires inside the case and glue it shut. The file above is a video of the speaker in action. It can go very loud or very quiet and the range of sound is nice.