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Last month we started talking about speaker boxes and the designs of them along with some things you need to know before you start building one. This month we are going to finish were we left off in the box building process. We talked briefly last month about the types of boxes this month we are going to talk about how to build an awesome enclosure. Before you get started you need some basic tools and supplies. If you don't have access to these basic tools and supplies I highly suggest purchasing them or let a local shop that does have these tools build your enclosure for you.1) Skill saw or Table saw- There is no other way to cut and build a box then without one of these two items. Don't burn up your dad's brand new jigsaw you bought him for Christmas trying to cut a 4x8 sheet of MDF. Hang it up and let someone else build your box.2) Jig Saw- This is a must for cutting the enclosure so your speaker will fit into your box unless you are lucky enough to own a router and hole jig.3) Nail or Brad Nail Gun- This one is a nice to have item but there are other ways to fasten the enclosure but if you have access to a 2" nail gun and compressor use it.4) Drill- You will need this puppy for a couple reasons. First you need to drill a hole for the jigsaw to cut your hole in your enclosure. Two if you don't have a Brad Nail gun this is your other option for fastening your enclosure together.5) Wood Screws-If you don't have access to the nail gun you are going to need a box of 2" tapered head wood screws.6) Wood Glue- This is what actually holds the box together and seals all your seams from leaking air.7) MDF or Birch- Medium Density Fiber board or Birch is the only type of wood that is acceptable to build an enclosure from. Birch will run you $ 40+ for a 4x8 sheet versus MDF that will run you 15+ at your local Home Depot. I strongly recommend ¾" MDF for all my enclosures unless I am building a high-end system then I use Birch.8) Framing and Speed Square- you want your box squared.9) Long straight edge- You will need to be able to mark lines over the length of the stock.10) Chalk Box- This is not a necessity but boy will it save you time.
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11) Tape measure- the better the tape the better your measurements. First I want to say that planning is the key to any box building project. You need to take careful measurements and make sure all of your measurements are double checked for accuracy. My granddad used to say measure twice and cut once. I believe in that old saying. You want to make sure your box is not going to get in the way of anything such as your seat or seat belts. Now that we have the design we want how do we know that it is the right air space for our sub. Well there is a simple math equation that we use to measure the airspace of and enclosure. Make sure that the measurements you are using are inside dimensions and not outside dimensions. This makes a major difference. Square or Rectangle enclosures: Height x Width x Depth divided by 1728 = Your Air space Wedge style such as those used behind a truck seat:Top + Bottom Divided by 2 x Height x Width divided by 1728 = Your Air Space Remember if there is a divider in your enclosure that you must subtract this from your airspace. Another thing that is often overlooked is that actual speaker itself takes up airspace for the cone and magnet structure so there need to be subtracted from the airspace of your enclosure as well. I do not divide boxes if both subs will be ran mono on one amp. Anything more the 2 subs you need to divide the box to keep the subs from canceling each other. First we want to lye out our pieces we will need on our stock. Remember try to cut as many pieces you can without wasting any stock. An example is we know our top, bottom, front and back are all the same width so lay these pieces out on our stock as to not waste any wood. A key thing is when you look at the enclosure from the front you don't want to see any seams or edges. You want your sides to sit inside you top and bottom and behind your front piece. If you are dividing the enclosure, make an extra side piece it is going to be the same size.
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