Sony Speaker Upgrade

I got tired of looking at the boring ol' black Sony stereo speakers in my living room so I decided to break them down and rebuild them. I decided to use 1/2" walnut plywood for the shell of the cabinets and 1/2" hickory for the front face. Since there is a science to the dimensions of a speaker cabinet including depth and where the bass port is, I decided to keep all the specs of the original cabinets. The only change that was made was I decided to include feet to raise them up from the floor. They are finished with a heavy coat of boiled linseed oil and couple coats of Deft spray lacquer. This is one of my favorite projects because I finally get to build something for myself that'll enhance my living room.

Step 1: Step 1: Cut Up the Speakers

The scariest part of the project was plunge cutting into the Sony speaker cabinets with my jig saw.

Step 2: Step 2: Cut the Cabinet Shell

I’m using 1/2” walnut plywood for the cabinet shell. Here I’m cutting 45° miters on all the edges.

Step 3: Step 3: Glue Up Cabinet

Using blue painters tape as my clamps, I glue up the cabinet shells.

Step 4: Step 4: Cut Out Speaker Holes

I drill out the mid-range and tweeter holes on the drill press and go back to the jigsaw for the woofer hole.

Step 5: Step 5: Glue the Face

Here I’m gluing and clamping the face into the cabinet.

Step 6: Step 6: Add Trim

Using my pin nailer I attach the face frame to cover up the plywood edges.

Step 7: Step 7: Add Feet

Since my speaker will stand on the floor I’m added walnut feet.

Step 8: Step 8: Wiring

And then I wire it all back up and attached the back panel.

Step 9: Finished!