From a long time I have been wanting to make cylindrical speaker enclosure out of wood something that resembles JBL FLIP series but I had absolutely no idea how to go about it. After quiet some good amount of online search I was not able to get any idea or guidance. I did find few cylindrical speakers but the cylinder shape was just the final housing whereas the inner airspace where the magnets of our driver will be was just the casual cuboid space or hexagon, nothing came out as a perfect cylinder. So a few days back an idea clicked in my mind that seemed to be practical and executable as per my experience and tools. I also had two tiny drivers of 27mm each which gave me another reason to start with this project as small driver means less wood and less work even if it goes in vain. Please keep in mind that this isn't a good sounding or good looking speaker project. Main aim of this project was to make a guide or blueprint that will help in construction of bigger and better cylindrical airspace enclosures so I have not given a lot of thought and time to how this speaker looks. Front side got badly damaged while making holes for drivers and the paint job was also done in a jiffy. Although it doesn't looks very neat but this project turned out to be a success for me as I finally had my wooden cylinder airspace enclosure. So here is my take at an easy way to make cylindrical airspace enclosure.
Step 1: Cutting and Preparing Wood.
First I made a small paper template and then placed it on a square piece of MDF 5x5cm to see if it fits. After that I decided to make 31 more pieces of 5x5cm.
Step 2: Layering.
After all 32 pieces were ready to use I equally divided them into 8 groups which means four of these pieces in one group. After that I glued together all the the pieces in each group that finally gave me thick 8 pieces of wood.
Step 3: Drilling Holes.
Once all 8 pieces were completely dried I marked a hole for drilling on each one of them. Holes I drilled are of 32mm
Step 4: Routing.
After drilling holes in all 8 pieces now it was time for some routing which will give the final shape to our pieces.
The areas represented by red and white arrows in first image were trimmed off with a palm router on my router table.
Step 5: Assembling Pieces.
Now that the pieces are in their final desired shape it was time to assemble all of them by sticking them side to side while making sure that there is perfect cylindrical hollow space as shown in image. I also made two extra pieces without holes in them as they were to be used as left and right panels.
Step 6: Sanding.
In order to get a smooth surface all over sanding was mandatory. I used 100 grit sandpaper for this.
Step 7: Mounting Drivers.
After assembling it was time to make holes for mounting our drivers. As the drivers were too small I had to use my palm router for it. Please keep in mind that in such kind of enclosure drivers can only be mounted from outside as there is no flat surface inside that can hold the drivers in place. Things did got messy while flush mounting but was not enough to discard this project.
Step 8: Paint.
For paint I just applied three thin layers of orange gloss spray paint .
After paint had dried I dropped this speaker few times to see if it as strong as a normal cuboid enclosure and also did the sound test to hear out any ugly vibration or distortion. In the end I was very much satisfied with my effort on making a guide for cylinder enclosures. You can also watch the video below if reading is not your thing.