DIY Tough Bluetooth Boombox (Lasts 20hrs!)

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Introduction: DIY Tough Bluetooth Boombox (Lasts 20hrs!)

About: Hi I'm Angelo! I am a college student taking my engineering majors in BS-EE/ BS-ECE at the DLSU. I use my course as an inspiration for making my current projects! I've been posting projects here ever since I...

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

Audio Modules & MISC:
- 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)
_____________________________________________________
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]

_____________________________________________________
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

Get your vernier caliper/ ruler then transfer your speaker's measurements by using a compass & marker.

Step 3: Drilling & Cutting

Here's my secret! Many are having a hard time making perfectly round speaker holes with a rotary tool. If you've ever heard of the "sanding drum bit", now is the perfect time to buy one. Start of by drilling a large hole inside your circular markings then sand of the excess plastic all the way to your markings. The Leatherman is sharp enough to cut the plastic, you can use it for the switch's hole. 

Step 4: Clean the Edges

The rotary tool has left a jagged texture. Clear this off with your Leatherman's ultra-sharp blade then sand it of with a 300-grit sandpaper.

Step 5: Mounting the Speakers & Bluetooth Panel

1st.)  Drill four holes for the woofer's screw mounts.
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

Here's a detailed wiring diagram, it's easy and simple! :D

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

Mount the PAM8403 amp module on both Left and Right speaker array. Refer to the image above for the wiring instruction.

Step 8: Finding a Good 5v Regulator

The PAM8403 needs a decent 5v regulator. The 7805 isn't enough to power two PAM8403 amp modules. Maybe it can, but by powering them with two separate 7805s. The 7805 is an outdated regulator, so better buy a 2 ampere USB car charger, it's much more effecient compared to having two 7805s. Plus the car charger's heat dissipation is much lower than the 7805s.

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

Since last year, I started using photosynthesized PCBs (presynthesized). It's much more cleaner and faster compared to the toner ink transfer method. You can still do the toner transfer method. The PCB layout (PDF) is provided below.

Learn To Fabricate PCBs:Click Here (Visit My Other Tutorial)

Step 10: Assembling the Mono Amp

Follow the photo above for the part's layout. Solder them to their respective pins. 

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

Since we have mono woofer, the woofer should share both left and right audio signals. 

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

I still had some LiPo batteries lying around in my workspace, I decided to use them for now. Lithium Polymer batteries serve as an excellent choice for long lasting power performance. The speaker can last for 18hrs @89dB, that's pretty good for an outstanding & punchy boombox. 

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!

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Third Prize in the
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3 People Made This Project!

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216 Discussions

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...

2 replies

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...).

Hay mate cool set up well done. I Would like to ask a question how come you did not use a ground loop isolater I have seen other builds that have one, I Am looking for info for a future build if my own thank you,

Hi there,
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?

Maybe somebody can help me out I bought an ammojamz speaker an it had the Bluetooth wiring harness an it was the power wires too, it melted an fried the circuit is there anyway that I can wire my amp straight to the batteries I have two 6 volt battieries wired to 12 volts an just play music off of the auxiliary port on the amp

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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

Do you need a Li-Po battery charger or can you use a a DC power supply connected to the mains?

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.

Capture.JPGCapture3.JPG

Hi, just wanting to know why the larger capacitor was installed on the PAM 8403 amp module and what size it is? Looking at trying to build this project very soon. Thanks

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

what kind of gauge wire did you use.Or what kind of wire should I use

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

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

Hej man nice job, but i dont understand, why not use the ground from the amps?

Someone actually used the TDA2005 amp circuit i designed. Kinda heartwarming. Glad to know it serves you well. Anyone getting a buzz or hiss from their speakers should reduce the input stage gain and use star earthing as far as possible in their equipment. Seperate digital and anaolgue ground! Cheers

Question is there any way this could be applied with a large full size speaker box i have a klipsch sitting around and i really dont want a surround sound but if i could convert it into a bluetooth unit it would be perfect

Fhank you jn advance

I'm not sure about tough when it comes to the speaker cones- they damage easily. They should be protected with a layer mesh to protect them as a speaker grill- there are stainless steel mesh sheets which would be very tough, even some of the nylon meshes would do a good job here.

I was just wondering.... shouldn't you seal the smaller speakers from the air pressure from the sub-woofer? It seems it would influence the frequencies the smaller speakers are capable of producing. GREAT PROJECT THOUGH!!!

Excellent project. I have been designing my own in my mind for ages, bought all the fun parts (bluetooth module, lipo, amp modules) but havent gotten around to making it all just yet.

The questions that i havent figured out yet: have you got a battery management system? How long out of one charge do you get? Have you pulled the guts from a 12v DC 2.1 system that was originally made to plug into AC (always on) power? Will this be a drain on the battery and what happens if your battery goes flat? Otherwise, excellent!