muhhan
28-02-2006, 12:13 AM
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!
Aim: To build a sealed sub box for a Alpine 12-inch sub that fits in the boot of EK civic
Required: Tools - jigsaw, table saw (optional), sanding block, coarse grit sand paper, file (optional), drill and 3mm drill bit, screw driver, rotary tool
Materials - 18mm MDF board, 8G x 40mm countersunk timber screws, wood glue, silicone sealant, Kwik Grip or spray adhesive, fabric
Steps:
1. Plan your design. Draw a scale diagram and measure to make sure its going to fit. Take your time at this stage, it'll make things run a whole lot smoother later!
2. Draw the individual pieces onto your MDF board.
3. Using a table saw, if you have one, or a jigsaw cut out the pieces as close to the lines as possible. Don't cut over them, you can always sand it back if it is a little big, but you can't add to it if you cut too much off. NOTE: When doing this you should wear safety glasses and a mask. Dust flies everywhere!
4. Sand back the pieces so that they are the correct sizes you drew up.
5. Test fit the pieces.
6. Mark out the speaker hole using a template or the speaker itself. Again, it's better if the hole is a little too small than a little too big otherwise you're going to have air leaking out.
7. Using the jigsaw test fit the sub. If it doesn't fit flush than sand down the edges. A rotary tool is perfect for this. Be patient, it took me about six times before the speaker would fit.
http://img207.imageshack.us/img207/7254/speakerhole8vx.jpg
8. Pre-drill pilot holes for the screws using the 3mm drill bit. You probably only them every 10cm, I just got a little excited! :D Screw your screws in so that the tip is just sitting flush with the first piece. This makes it easier when you start screwing it together.
http://img234.imageshack.us/img234/329/screwing3bz.jpg
9. Run a bead of wood glue on the joint before you put the piece into position and start screwing.
10. I like to continually test fit the pieces as I go to make sure that everything is working out. Here you can see that the front piece is not screwed on yet.
http://img56.imageshack.us/img56/2710/testfit5jp.jpg
11. After you've got most of the pieces into position apply some silicone sealant to the seams. This will make it airtight.
http://img154.imageshack.us/img154/751/silicone4jl.jpg
12. OK, back from my break now. Now's a good time to get some sound deadening material in there while you can still fit your mitts in. This step is optional. Cut the material to size.
http://img228.imageshack.us/img228/3972/cutting0in.jpg
Stick it on using spray adhesive or Kwik Grip.
http://img116.imageshack.us/img116/5118/kwikgrip7gz.jpg
http://img122.imageshack.us/img122/8598/spreadadhesive2bb.jpg
13. Fix the final piece down. The box is essentially completed. Notice all the sound deadending goodness inside.
http://img70.imageshack.us/img70/4334/lastpiece2ck.jpg
http://img210.imageshack.us/img210/708/boxcomplete4hs.jpg
14. OK. Here's the final step, carpetting the box. You can pretty much choose any fabric you like, I used polyester fleece. Cut the fabric into the rough size for your box. Here you can use spray adhesive. Spray onto both surfaced and wait until it goes a little tacky then place the box on the fabric. I started from the bottom and pulled the fabric around gluing each side as I came to it. Just make sure the fabric is pulled so that no wrinkles or creased are in it. After leaving it to dry trim the excess off using fabric scissors and cut the hole for the sub using a blade.
http://img56.imageshack.us/img56/7394/carpetted8on.jpg
Other comments: Sorry about the lack of images I only thought about doing a DIY half way through the project. Thanks for reading! :wave:
Aim: To build a sealed sub box for a Alpine 12-inch sub that fits in the boot of EK civic
Required: Tools - jigsaw, table saw (optional), sanding block, coarse grit sand paper, file (optional), drill and 3mm drill bit, screw driver, rotary tool
Materials - 18mm MDF board, 8G x 40mm countersunk timber screws, wood glue, silicone sealant, Kwik Grip or spray adhesive, fabric
Steps:
1. Plan your design. Draw a scale diagram and measure to make sure its going to fit. Take your time at this stage, it'll make things run a whole lot smoother later!
2. Draw the individual pieces onto your MDF board.
3. Using a table saw, if you have one, or a jigsaw cut out the pieces as close to the lines as possible. Don't cut over them, you can always sand it back if it is a little big, but you can't add to it if you cut too much off. NOTE: When doing this you should wear safety glasses and a mask. Dust flies everywhere!
4. Sand back the pieces so that they are the correct sizes you drew up.
5. Test fit the pieces.
6. Mark out the speaker hole using a template or the speaker itself. Again, it's better if the hole is a little too small than a little too big otherwise you're going to have air leaking out.
7. Using the jigsaw test fit the sub. If it doesn't fit flush than sand down the edges. A rotary tool is perfect for this. Be patient, it took me about six times before the speaker would fit.
http://img207.imageshack.us/img207/7254/speakerhole8vx.jpg
8. Pre-drill pilot holes for the screws using the 3mm drill bit. You probably only them every 10cm, I just got a little excited! :D Screw your screws in so that the tip is just sitting flush with the first piece. This makes it easier when you start screwing it together.
http://img234.imageshack.us/img234/329/screwing3bz.jpg
9. Run a bead of wood glue on the joint before you put the piece into position and start screwing.
10. I like to continually test fit the pieces as I go to make sure that everything is working out. Here you can see that the front piece is not screwed on yet.
http://img56.imageshack.us/img56/2710/testfit5jp.jpg
11. After you've got most of the pieces into position apply some silicone sealant to the seams. This will make it airtight.
http://img154.imageshack.us/img154/751/silicone4jl.jpg
12. OK, back from my break now. Now's a good time to get some sound deadening material in there while you can still fit your mitts in. This step is optional. Cut the material to size.
http://img228.imageshack.us/img228/3972/cutting0in.jpg
Stick it on using spray adhesive or Kwik Grip.
http://img116.imageshack.us/img116/5118/kwikgrip7gz.jpg
http://img122.imageshack.us/img122/8598/spreadadhesive2bb.jpg
13. Fix the final piece down. The box is essentially completed. Notice all the sound deadending goodness inside.
http://img70.imageshack.us/img70/4334/lastpiece2ck.jpg
http://img210.imageshack.us/img210/708/boxcomplete4hs.jpg
14. OK. Here's the final step, carpetting the box. You can pretty much choose any fabric you like, I used polyester fleece. Cut the fabric into the rough size for your box. Here you can use spray adhesive. Spray onto both surfaced and wait until it goes a little tacky then place the box on the fabric. I started from the bottom and pulled the fabric around gluing each side as I came to it. Just make sure the fabric is pulled so that no wrinkles or creased are in it. After leaving it to dry trim the excess off using fabric scissors and cut the hole for the sub using a blade.
http://img56.imageshack.us/img56/7394/carpetted8on.jpg
Other comments: Sorry about the lack of images I only thought about doing a DIY half way through the project. Thanks for reading! :wave: