Wireless Bicycle Mounted Bluetooth Speaker

9,954

93

15

About: Nice to meet you! I'm Donny from Lithuania and I have a passion for designing aesthetic, yet durable and practical projects. Check my YouTube channel for more! ▶ http://www.youtube.com/c/DonnyTerek

Hi there!

In this Instructable I will show you how I have built my wireless bicycle mounted Bluetooth speaker. I have to say, this might be one of my favorite projects so far. It looks great, has great sound and has that futuristic appearance! As always, I will include the build plans, laser-cut plans, the wiring diagram and of course the list of the parts and tools that were used in this build. Make sure to watch my YouTube video first and then come back for further details of the build. Let’s dig in!

Step 1: Components and Plans

Make sure to check out the wiring diagram and all the plans included if you would like to build a speaker like this one yourself! Feel free to download it and zoom in for a better view.

COMPONENTS:

TOOLS and MATERIALS:

Step 2: Important to Notice!

Even though it is self-explanatory it is worth mentioning that everyone’s enclosure’s size and shape will depend on the bike frame that you have. Therefore make sure you check that the enclosure will not obstruct any movement of the pedals and cranks or the suspension components if you have a full suspension bike. To do that you can simply cut a few pieces of cardboard in a shape of the speaker enclosure and check the fitment and cut the cardboard accordingly to achieve a great fit.

Therefore I am only including a picture of my enclosure's build plans so that you can get an idea of how the parts should look. Notice that some panels have an angled cut so that they fit nicely along each other.

Step 3: Building the Enclosure

For the main building material I chose 12mm MDF which I love working with. It is sturdy, strong and can be painted over with not much effort.

I used the tablesaw and a jigsaw to cut the pieces to required dimensions. I sanded the edges to achieve the necessary angles for the box to be glued without blank spaces.

To cut out the circles for the speakers I used a wood router with a circle jig. You can also use a jigsaw for that manner since the edges do not need to be perfect because the speaker will be mounted on top. I also used a combination of router bits for the plywood panel to sit flush with the surface of the speaker.

Step 4: Glue Up!

Healthy amounts of wood glue on the edges of the panels to ensure a strong bond between the pieces. Using a plastic card I spread the glue evenly along the edge. Make sure to use a square when gluing the panels together!

Step 5: Treating the Edges

Once the glue has dried, off camera I have glued in the support pieces for the side panel to be screwed in. I also sanded the sharp edges smooth and round. Using a roundover bit I ran across the outer edges of the enclosure making them round and smooth to the touch. A dust mask and dust collection must be used for this step which includes lots of MDF dust!

Step 6: Painting the Enclosure and Plywood Pieces

To paint the enclosure with the colour of choice, first of all we need to tackle the tricky nature of MDF panels which is its ability to absorb lots of liquid including paint that contatcs its surface. In order to achieve a nice paint finish on the MDF we need to create a thick layer or a coat that would not absorb the paint in to the pores. Since I could not source a simple sealant for MDF in my country, I went with a 50-50 mixture of water and Titebond III. I chose Titebond III since it is used for outdoor use and will not be penetrated by liquids. I simply mixed the two and brushed a thick coat of it on the MDF enclosure and then letting it thoroughly dry overnight.

Once the sealant has fully dried you can see that the surface is glossy and is actually really smooth to the touch. It is now ready for paint. Before our color coat we need to seal the panels with a thin coat of primer to smooth out the surface even more. Before spraying the primer I scuffed the enclosure’s surface with some 200-400 grit sandpaper.

While the primer was drying I sprayed the laser-cut plywood pieces with a few coats of clear lacquer to make the wood a bit resistant to outdoors.

Off camera I sprayed my colour of choice which is matte black on the enclosure once the primer has fully dried.

Step 7: Electronics!

I did include a wiring diagram in Step 1 for this build so make sure you take a look!

For the battery I used six 18650 Lithium Ion cells with a capacity of around 2700mAh connected in a 3S2P configuration. 3S means three batteries are connected in series resulting in a voltage of 12.6V. 2P means that there are two 3S packs wired in parallel, resulting in a battery pack with a voltage of 12.6V and a capacity of around 5.4Ah. That means that the battery will be able to provide nearly 50 Watts of power for over an hour!

The cells are connected to a BMS (Battery Management System) board which makes sure that all the cells are charged to the same voltage which is very important for the longevity and overall safety of the battery pack. I think this board is great since it has short-circuit, over charge and over discharge protection and even a temperature sensor! (I did not use it on this battery pack)

Just to play it safe, I stuck a piece of adhesive foam on the ends of the battery to protect it from any shorts. I also wrapped the contacts and the whole pack with kapton tape.

Then according to the wiring diagram I soldered all the connections and began putting the components inside the enclosure making sure to use plenty of hot glue to hold the components in place.

Step 8: Sealing the Enclosure

Super important step! Making sure to seal the enclosure so that no air escapes once the speaker is working. For that I used a single sided adhesive foam strip across the edges of the enclosure. I also applied glue around the switches, blue LED and ports that were mounted on the plywood control panel to make sure that the enclosure is air-tight.

Step 9: Mounting Hardware

To mount the speaker to the bicycle frame I used 4 velcro straps on the top of the enclosure and 2 straps on the bottom. For this build I made my own velcro straps which to my mind are better lasting and have a better grip to the bicycle frame. I also placed a strip of soft adhesive foam across the top and the bottom side of the enclosure to protect it from ant bumps in to the bike frame.

Step 10: Last Steps!

Just a few thing left to do to finish the speaker, such as screwing the control panel in place, gluing on the volume knob, placing sealant strip around the speaker holes, screwing the panel in place, placing the speakers and the grills on top of them.

Step 11: Final Thoughts

All that is left to do is screw the logo in place and we have the finished speaker! I am truly happy of how it turned out. It is tightly held in place with the velcro straps even though the speaker does weigh some. Since I finished this build in the middle of the winter, I did not have an opportunity to get outside to test this speaker while riding the bike. But strolling across one room to another it seems it would hold up well to riding. It takes a few hours to charge the speaker up. The Bluetooth 4.2 connectivity is amazing, the range is great even through a few walls around the apartment. You can also hear the voice prompts of the Bluetooth module letting you know when the module is connected to your device. And I have to say, the connection is instant as you can see in the video! It sounds great and is plenty loud for outdoor use.

Thank you for tuning in with me to this project! Hope you had fun and maybe learnt something new from this one! Make sure to take a look at my other projects and YouTube videos and I will see you on the next project!

- Donny

Epilog X Contest

Runner Up in the
Epilog X Contest

Share

    Recommendations

    • Sew Tough Challenge

      Sew Tough Challenge
    • Sensors Contest

      Sensors Contest
    • DIY Summer Camp Contest

      DIY Summer Camp Contest

    15 Discussions

    0
    None
    arduinomaster

    3 months ago

    How do I vote on this , no vote button here?

    0
    None
    mohammad_hasan

    5 months ago

    Good idea nice work i am mohammad from egypt i used to degsin soud systems low and high power

    1 reply
    0
    None
    fkbae

    6 months ago

    Wow, I'm planning to build a similar speaker for my old bicycle and just discovered this. Thank you for a detailed post. This would be very helpful!

    1 reply
    0
    None
    Donny Terekfkbae

    Reply 6 months ago

    Thank you! Feel free to ask any questions if you have any. Best of luck on your build and would love to see it once finished!

    0
    None
    laflaf3d

    6 months ago

    Even if your work is great and well made, I am aware that this kind of product is not very cool for people who didn't ask to hear music or dislike the music's style that's spit out. It's like noise pollution product.

    1 reply
    0
    None
    Donny Tereklaflaf3d

    Reply 6 months ago

    Thank you for the comment! With all the respect to other people, this speaker will not be used in public places where others can hear it. It will be mainly used outdoors with minimal number of people around.

    0
    None
    CaptClaude

    6 months ago

    I really like this -- not so much for the particular design but for the completeness, finishing and attention to detail. I have some experience with bike-mounted speakers (I'm not in the UK so those ridiculous laws don't apply to me) for group rides like Critical Mass. I simply don't have the patience to document things well enough for an Instructable :-(.

    tube speakers.png
    1 reply
    0
    None
    Donny TerekCaptClaude

    Reply 6 months ago

    Thank you so much for the kind comment! Yours is a truly different approach I have to say, but looks just as great!

    1
    None
    GothBoyUK

    6 months ago

    It is worth noting that the use of the speaker in the UK would be illegal under various pieces of legislation without a licence to do so from the Local Authority. If I remember correctly, although it has been a few years since I last worked in enforcement, it was under COPA 1974 that a vehicle (which would cover a bicycle of this type) with a loudspeaker required a specific permit if used where the public could hear (pretty much anywhere unless you owned vast tracts of private land).

    1 reply
    0
    None
    Donny TerekGothBoyUK

    Reply 6 months ago

    Hi! Thank you for the comment. By no means will this speaker be used where the public could hear. It will mainly be used riding outdoors, mainly in the woods where not many people would be bothered by a few tunes while riding.

    0
    None
    SeanB10

    6 months ago

    This is profoundly relevant to my interests. While my """phone""" does GPS recording and music playing, my bicycle needs bright rechargeable lights, I've settled on the programmable kind. However housing the electronics, and speakers, and especially tying all the parts together, the 18650 cells and charger, step up/step down boards, amp, like adult Legos, has been a challenge. I have a couple of waterproof speakers and what not, but need to up my power game. Your circuit diagram is a real keeper! Excellent work!

    1 reply
    0
    None
    audreyobscura

    6 months ago

    This is such a great design! It looks great in your bike frame!

    1 reply