Hi there my name is Sammy 1 Thumb. I will do my best to explain how i built my bluetooth speaker tower.
First thing this was made of reclaimed pallet wood. The planks were 1 1/2 inches thick by 9 inches wide. The top and bottom made from ply wood just 1/4 inch thick. This was my first speaker box i have ever made, but i can say it turned out really well.
A little tricky in some spots but hey when you are using reclaimed wood that has been used for another purpose things can get tricky. So enough of the chit chat lets get to step one.
Step 1: Ok So on to Step One.
Alright step one was the scariest part of this build. I had to determine how long/tall i wanted the box to be. Knowing the width was exactly where i wanted it. I was most nervous about the thickness of the wood and any warps/bends in the wood. Now each plank was only 43 inches tall and i needed 4 sides, so I had to find a good middle ground. I cut the 2 planks into 4 planks at 20 inches each. Now that i got my cuts done to the lengths desired it was on to the edges.
I got my table saw ready, well not my table saw given the fact that i had to borrow it. Regardless I set the blade to 45º because 45 plus 45 makes a 90º corner. This is where some things got tricky the wood on one of the edges was a little cracked so when i cut the angle it chipped off a chunk. I had to roll with it, given that this was the only wood i had for it.
I knew that it was thick enough that when i glued it, it would be sealed. After all the angles were cut I picked one of the planks for the speakers. I am using 2 oversized 6.5s with no hole saws. I used a jigsaw. I found the center no special tools just the old fashioned way by eye and judging with my fingers. I flipped the speakers upside down marked my holes where my speaker would be screwed in at. To make the holes for the speakers to rest in I used a kitchen utensil holder. It was dang near perfect. I traced the bottom of the holder on the chosen plank. To cut the holes out i took my drill with a 5/8 drill bit to make a starting point for my jigsaw. Now this part was tough the thickness of the wood and trying to work the jigsaw in a curved pattern the whole cut. Just steady and slow is the key.
Step 2: Glueing the Box Together.
I know in my previous step you seen images of my box already glued. I did not think to take pictures of the wood previous to that sorry. This was an easier part of this project. After the angles were cut I laid out the planks side by side. I used masking tape to tape the pieces together with the out side facing up, the angle cuts facing down. After I put a healthy amount of tape on i turned all of it over as one with now the back sides facing down and the angles facing up. I used gorilla wood glue to fill in the angles. For this you need to put a lot of wood glue to ensure that it will be a great bond ( no leaks).
Now that i added a healthy amount of glue I started from one end and folded it up then the next piece folding it over. If you get what i am saying. For the final piece you add glue to the 2 ends and mate them together by bringing the opposite end up to meet the folded over end.
As you mate them together you get your tape out again and firmly tape the gap together to hold it in place. You also add more tape on all sides to bring it tighter together. A wonderful trick i learned from kirby off youtube. Thank you kirby. Now just letting the glue dry is the final step with this part.
Step 3: Staining the Box.
Staining wood is relatively easy just like painting but with a thinner liquid. Every time i go to stain wood i never have gloves. Buy gloves really i mean it buy gloves. If your like me and have no gloves a good old walmart sack works alright. Sad i know i used a walmart sack. Besides my lack of gloves to spread the stain around i just use an old sock that probably has reached its limit any ways.
You dip your sock, piece of cloth, sponge, or what ever you have to be used in this step and start spreading it around in smooth strokes. Just like painting but cooler you get to see it change the wood in front of your eyes. The grain starts coming out to be seen and it just really makes it look brand new. Even for a piece of reclaimed junky wood it can bring it back to life. Now i like a darker wood but not super dark. I went with a dark walnut stain I love it. I also stained a cane i built with the same stain just love it. Ok so after staining the whole box it is just time to let it dry. The next thing to do after drying is to lacquer it. Now i just used a spray lacquer on it it does the trick well enough. I used a good couple of coats to bring out the shine. Maybe could have done a couple more coats but i knew i needed what i had left for my next step, and that is building the table. So lets do it lets build a table.
Step 4: Building the Table.
For the table i used one solid 2 by 4 plank of what seemed to be cedar. Again i used reclaimed wood. I can tell you this it was dense scary dense. Let me explain the plank was 46 inches long and i needed 4 legs from it. So i cut it down to two 22 and 1/2 pieces. Than after doing that i needed to cut the halfs into halfs but long ways. So i set my table saw to 2 inches. As i start cutting this is where it got scary, the wood was so dense that it started to jump on the table saw. I had to force it down with one hand as i was pushing with the other. Just waiting for it to let loose and bam messing me up good. I had to back out and go again a few times to clear that spot it took like 3 minutes to finish the one half. I don't know if it was treated or what the deal was but remember always be safe and at the ready.
Moving on. I got the legs cut to size finally, with now stained underwear, and set them off to the side.
For the table top I knew i wanted it to be just a bit bigger than the box. So I cut out a ten inch square out of the same 1/4 inch plywood.
Now i just have to glue the pieces together no screws just glue. So one leg at a time I glued the legs to the table top with the same gorilla wood glue. I used a bar clamp to press the legs to the table top. This was the longest process given that i have only one bar clamp big enough to use. After all the legs were finished drying i gave it a dry run and mounted the box on the table. Just testing to see if it would wobble or fall easily. Sturdy as a rock.
The finishing touches on this table are the skirting around the bottom of the table top. I took some red wood cut it into sections to fit between the legs. Each section is an inch thick or tall how ever you want to say it. Having a brain fart explaining this part. Ok I did cut them a bit to long just a hair so i could sand them down to ensure a snug fit. After reaching the perfectly snug size i glued them into place on three sides. The ends that touched the legs and the whole length that touched the top. Then i used 2 C clamps to make sure that both sides glued evenly and tight.
Next is staining it. Same as before with the box grabbed that sock, but instead of the walmart sack i did find a glove that had the rubber palm and fingers. Much better than that walmart sack. Now just waiting on that to dry and on to the lacquer.
Well that's it i want to thank you guys for reading this and hope you find any of this useful as well as enjoyable.