This article was first published in the August 2015 issue of WIRED magazine. Be the first to read WIRED's articles in print before they're posted online, and get your hands on loads of additional content by subscribing online
So your car's puny stereo isn't living up to its neighbourhood-shaking potential? Just add a subwoofer. You'll also need a box to mount it in, which can, of course, be bought, but why not build one? Maker Jonathan Neumann created a setup that "hit hard, had great mid- and low-range notes but kept the music clean". Here's how you can reclaim your street cred.
Plan your buildFor his build, Neumann needed to fit a 31cm speaker, which the manufacturer said should be in a 21,000cm3 to 35,000cm3 enclosure. His recommendation is to design a box that will fit your speaker and trunk, at least 5cm deeper than your subwoofer. Multiply length x height x depth of the box's interior (subtract twice the width of your materials) to obtain your specs.
Acquire the partsFor your custom speaker box, you'll need a subwoofer and 20mm MDF (cut with a table or circular saw, or have the DIY shop cut it). You'll also need a drill, pencil, tape measure, ruler, jigsaw, string and box cutter. Obtain 40mm-long wood screws, caulk, carpet and spray adhesive. A speaker terminal cup, as well as 12-16-gauge speaker wire, is also needed.
Cut your MDFCut the front piece of MDF that will hold your speaker, as well as the back MDF section into the full height of your design, and the width of your design minus twice the material thickness (40mm). The top and bottom will be the same length as the front section in one direction by the depth dimension minus twice the thickness (40mm) in the other. Also cut two side pieces.
Attach the boxDrill two sets of pilot holes on each section, evenly spaced 10mm from the edges. Do the same for the sides, and drill four evenly spaced holes on each long edge, and one or two extra holes on the short edges. Place the front section on the top and bottom pieces aligned with the holes and secure with wood screws using the pilot drill. Repeat for the back.
Add the finishing touchesApply caulk to the inside edges of the box to form a good seal and let it dry. Apply spray adhesive and cover with carpet. Cut the final side with a box cutter, letting the edges meet as seamlessly as possible. Cut out material for the side pieces and apply in a similar manner. Cut off excess material, as well as the holes for your speaker and the terminal cup.
Fit your subwooferCentre your terminal cup and secure with screws, drilling pilot holes as appropriate. Attach wires from your subwoofer to the terminal cap. Lower the subwoofer into the large hole and mount with wood screws. Tighten in a star pattern like a car's wheel, making sure not to let the driver slip off and penetrate the surround or cone of your speaker.
This article was originally published by WIRED UK
