Here goes nothing. Guess the place to start is the beginning. This is my first Instructable. I found this beautiful looking champagne box and was wondering what I could use it for. I decided to use some old PC speakers and try my hand at creating my first 'Folded Horn Speaker' I also wanted to make the speaker self-powered. What I created doesn't sound half bad and also amplifies the sound coming out of the box giving a full room sound experience. Most folded horns usually have longer dimensions from front to back.
In building my enclosure inside the champagne box, I used birch plywood which I had on hand. It makes a very good speaker box, as most hardwoods do. However, the best choice is MDF (Medium Density Fiberboard). Here's a few ideas to toot your own horn with.
- According to Wikipedia, a horn loudspeaker is a loudspeaker or loudspeaker element which uses an acoustic horn to increase the overall efficiency of the driving element(s).
- Audio Judgement explains the concepts of how folded speaker horns work.
- A quick Google Image search will show different designs of folded speaker horns.
Step 1: Step 1: Supplies Needed
- 1 Wood Champagne Box or similar Recycled Box
- Self-Powered Computer Speaker (preferably full-range driver)
- Hardwood or MDF (MDF easier to work with and better for sound)
- Handsaw or Table saw
- Wood Glue
- Palm Sander or Sand Paper
- Tape Measure
- Drill & Drill Bit
- Speaker Gasket Tape
Step 2: Step 2: Cutting Your Pieces
Measure the inner dimensions of your recycled box which will house your speaker enclosure. This will determine the length, height and depth of the boards. Use a hand saw or table saw to cut your pieces.
Step 3: Step 3: Assemble the Box
Use generous amounts of wood glue to assemble part of the box. Focus on assembling the back, the left OR right side, and the top and bottom. You will also glue the board that divides the power supply from the speaker chamber. You are leaving one side and the front open so you can build your inner chambers. I chose to assemble the left side as you can see in the picture. Using a good amount of wood glue helps seal the box and make it airtight as much as possible, which creates better sound. Caulk can also be used for this purpose of creating a good seal, added after the wood glue is dry. Before moving on to making your chambers you'll need to drill two holes. One for the power supply line and 3.5 mm jack to pass out of box and the other smaller hole to pass speaker wires into driver chamber.
Step 4: Step 4: Building the Folded Horn
Building a folded horn can be a very complicated process. A lot of numbers go into each chamber in the progression of speaker to the exiting of the horn.
Here are a few programs to help you along.
Step 5: Step 5: Closing It Up
Here comes the tricky part. Add glue to every piece that will come in contact with the side board to make sure each chamber fold and outer box wall is sealed completely (optional would be Speaker Gasket Tape).
Step 6: Step 6: Almost There
If you haven't already, measure the hole needed to mount the speaker and add some speaker tape to seal speaker. Make sure you don't touch the tape to the cone. Depending on how your speaker chamber is made is where you'll place your speaker on the front faceplate. Mount your power supply in the topmost chamber of box, passing the speaker wires through the hole next to it and the 3.5 mm jack out the back hole. Place speaker gasket tape around outer rim of box that will hold the front faceplate. With speaker mount in the front faceplate, connect speaker wires to speaker and put faceplate into place. Drill a hole in each corner of faceplate with a smaller bit than the screws used. Once the box and everything is assembled, you should be able to combine the box with the outer shell.
Step 7: Step 7: Time to Fire It Up
Time to let it blow. The music will probably sound distorted close to the box, but as you move away it will sound better. It takes a little distance for the sound waves to assemble back in order.
I know this is my first Instructable and hopefully not my last. I hope to get better at doing these. Only time will tell. What started as a fun little project has inspired me to go deeper into my understanding and knowledge of sound and speaker-building. If you like this Instructable, please vote and let me know if you'd like to see more. My future projects will come from found speakers at thrift stores, and figuring out ways to enhance the quality and sound.