Construction


When you are starting to put it together, you will want to draw out each piece of the enclosure before you start cutting them so that you don't waste any of your material. Once you cut each section, you will have to put it together for a second to make sure the pieces fit together nicely. One option that you will have to consider at this point is the use of the braces for the inside, which, may result in a sturdier box in the end. Usually, this will be 1.5 inch x 1.5 inch strips of material. Most of the time, you'll need to add braces only for boxes that have internal volumes of more than 5 cubic feet anyway.

In the end, if all of the pieces fit and the edges match up, the box is ready for permanent assembly. First of all, you will have to make sure all of the joints are free of clutter and debris and dust etc. next you will have to slowly run a bead of carpenter's glue along the line where you'll be making the first joint. Carefully put the two pieces together and secure them by using screws or nails.

You are going to want to use one screw every 6 inches or one nail every 3 inches. If you're using screws, you have to drill pilot holes to prevent the wood from splitting on you. If youre hoping for a more polished look, countersink the screws. You should note that the type of joint that you choose to use is not critical as long as the box is strong and airtight.

Keep putting the box together but don't attach the baffle board just yet. This is the front panel that holds the speakers. Dont out it together until you've made sure the enclosure is sealed. To do this, fill a caulking gun with silicone sealant and run a bead along the inside of each joint. After you have caulked the box, secure the baffle board in place.

With the box assembled, you are now ready to cut the speaker openings and the vent, if you've chosen to go with a vented design. I've always found that it's easier to work on the wood once the box is already put together. The vent tube can be made of plastic, cardboard, or even wood if you want. First, you have to calculate the center of each hole and draw a circle with your compass. Make 3/8-inch starter holes with a drill and then cut out the holes using the jigsaw.

Once you have the speaker and port openings are cut, you need to put some silicone sealant on the tip of your index finger and reach all the way into the enclosure to seal the inside joints of the baffle board. It's very important for you remember that the enclosure has to be completely airtight because air leakage reduces the system's power-handling capacity and causes distortion. Once the joints are sealed, you will need to start covering three. When you do this it will help minimize mid bass resonances.

At the end
How you enclosure looks is strictly a matter of personal taste. Although you may not think it's important, most people want the cabinet to complement the vehicle's interior. In general, you will find that spray adhesives are used to bond fabric to the surface of an enclosure. This is when you'll need your razor knife to trim away excess material and cut around the speaker openings for a custom fit.

Mounting the Drivers
Before you start mounting the speakers, you'll need to drill a few holes. First make a hole at the bottom of the enclosure's back panel where you will have the speaker-cable connector. Now you will have to put the drivers in the holes and mark the location of each screw hole with a pencil so that you can easily find them. Remove the speaker and drill pilot holes.

Remove all wood shavings before you go on to the next part. Here is where you will have to grab a generous length of speaker cable through the hole in the rear of the enclosure for obvious reasons. Then mount the connector of your choice and, use your finger to seal the opening with silicone.

Hook the speaker wire to the connector. If you don't use connectors, tie a knot in the speaker cable at the point where it exits the enclosure. Mount your crossover devices, and wire the cables to the speakers. With all wires securely in place you have to secure the drivers to the baffle board and take a screwdriver-size hole in the speaker.

Securing the Enclosure
Once your box is complete, all you have to do is secure it in the vehicle. You can use L-brackets for this which is good enough or you can remove the drivers and bolt the box directly to the vehicle.

Lastly, you need to connect your new creation to you overall power source and start listening to the job you did. As a last bit of advice for your enclosure, patience is key. Dont be too easily disappointed if your efforts dont work right away as it can sometimes take practice.

Of course, you may now wonder what is next. Well, I realized that I talked a lot about wires and speakers, and didnt mention much about them. That is what our next section is going to cover.