This is a tutorial on how to build the overnight sensations speaker kit from parts express.
Step 1: Parts Needed
1. Overnight Sensation s Speakers from parts express (https://www.parts-express.com/overnight-sensations...
2. Clamps to hold speaker parts in place
3. Wood glue
4. Wood Filler
5. Palm sander
6. Wood Stain
7. Polyurethane finish
8. Foam brushes
9. 2 pieces of Ply-wood for the crossovers
10. Speaker binding posts
13. Amplifier (https://www.parts-express.com/dayton-audio-dta-21bt-100w-class-d-21-amplifier-with-bluetooth-and-power-supply--300-3830)
14. 8 small screws
Step 2: Glue Speaker Pieces Together
To glue the speaker pieces together, align the sides, top, and bottom and apply glue to all of the edges. Glue them together and put clamps on the top and bottom so that they touch both sides and tighten them. Let it sit for an hour and then glue the front piece on the structure. Don't glue the back piece on so we can put the electronics and the speaker drivers inside the casing.
Step 3: Sand the Speaker Casing
To sand the speaker casing, use a table and some clamps to hold the casing in position. Then lightly sand with 120 grit sandpaper. Don't over-sand the casing otherwise, it will damage the wood. After that, sand with 220 grit sandpaper to make everything smooth. Keep sanding until the wood has a smooth texture. Also, blow off any wood dust to make sure that the surface is smooth and ready to be stained.
Step 4: Stain the Speaker Casing
Before staining the speaker casing, use a pre-stain solution and coat each side with it. Then wait for an hour for it to dry. Next, open your can of stain and use a foam brush to slowly stain each side of the casing. Make sure to wipe any excess from each side. Now let the stain sit for a day so that it can dry off and be absorbed by the wood.
Step 5: Sand the Casing Again
After the stain is dry, lightly sand the casing again with 220 grit sandpaper to get rid of the excess stain and to smoothen the surface. Next, reapply the stain to the smoothened surface and let it sit for a few hours. Now the surface should be very smooth.
Step 6: Apply the Polyurethane Finish
Now apply the polyurethane finish to the stained wood. Apply one coat with a foam brush and wait for 2 hours. Then apply a second coat for good measure and let it sit for a day.
Step 7: Do Steps 2-6 for the Other Speaker
Step 8: Assemble the Crossover Board
Now assemble the crossover board. On my board, I have written the speaker driver's and tweeter's positive and negative connections.
Step 9: Test If Your Connections Work
Connect the speaker driver and the tweeter to the crossover board using crocodile cables. Also, connect the crossover to the amplifier. Turn on the amplifier and connect some external audio input and test if your connections work.
Step 10: Solder Speaker Wire to the Speaker Driver and Tweeter
Solder speaker wire to the driver and tweeter before attaching them to the speaker casing
Step 11: Attach the Speaker Driver and Tweeter
Attach the speaker driver to the casing using 4 small screws. And use super glue to attach the tweeter to the casing,
Step 12: Fix the Port Onto the Back Plate
Screw the port into the back plate using 4 small screws
Step 13: Solder Speaker Wires to the Crossover
Solder the speaker wires to their respective positions on the crossover. Then attach the crossover's positive and negative to the speaker-binding posts that were drilled into the back piece.
Step 14: Complete Your Speaker!
Glue the back plate onto the speaker casing, and connect the positive and negative wires to your amplifier