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Thread: Sub Woofer Construction Project

  1. #1
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Hello Everyone,

    I have been working hard and have switched shifts twice. These types of changes ruin your ability to have side projects, but offer the earnings to replace older things. Mrs. Shocksystem and I watch a lot of films (very little TV) and have made some major changes in our home theater system. We have replaced our Sony 32in True Flat Trinitron with a Sharp Aquos 52in High Contrast LCD, and we have swapped our older Pioneer analog 5.1 Pro Logic Surround Sound System for a new Onkyo 7.2 HDMI Dolby Digital Pro Logic / DTS System.

    Part of the upgrade involves replacing our existing speakers (JBL T601 Monitors – High Level of Awesome!) with new custom hand built speaker systems including a new Sub Woofer Cabinet.

    I figured I would document my progress.

    Please feel free to comment and add suggestions!

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  3. #2
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    This is the basic component - 35in wide by 2ft tall and 19in deep.

    This should rival the local (18 miles away) theater. I have an Adcom GS 5200, 50watt RMS amplifier that is old, but solid and very functional to power the whole contraption. I think that I can have a premier, clean sounding, tooth rattling system with little money. The base unit is made of 3/4 in MDF particle board scraps from a door shop acquired at no cost (staple removal at your own risk).

    The system will contain two old 12in / 120watt Majestic Car Audio Sub woofers (4 ohm) acquired for under $40.00 in good condition - Unused and unmounted but stored for an extended period.
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  5. #3
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    I sketched the design and started wok quickly.

    I used flat black paint to check the edges and fit of the box when sanding. I sketched out the basic port design on the box once the construction started. Because it is so large, I wanted a unique and interesting design, the drivers will remain hidden inside the enclosure.
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  7. #4
    Stuey - The RADministrator MrGneiss's Avatar
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    Default Re: Sub Woofer Construction Project

    Are you sure its Big enough??

    "Blowing smoke rings at the moon."

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  9. #5
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Here is the design sketch, in line with the actual enclosure.
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  11. #6
    Sandwich Shooter ShockSystem's Avatar
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    Default Re: Sub Woofer Construction Project

    Mrs. ShockSystem made the statement: "This thing better Kick Ass, otherwise you need to build it bigger". I follow instructions very well.

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  13. #7
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Base enclosure with the divider in place.
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    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    The Main Compound Load Port is now cut.

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  17. #9
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Here are is the picture of the forward firing main port and the secondary chamber ports.
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  19. #10
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Here is the first of two 12in Sub Woofers mounted on it's chamber separator. The ports will fire forward (toward the listener) and the sub will fire into the tuned chamber.
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  21. #11
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Here is a test fit of the separator chamber and a view of the face and how the magnet and back of the speaker cone will look to the listener. This was a check of the port depths - They must seat evenly and seal completely from the center chamber or the sound quality and power will be less than desirable.
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  23. #12
    Goodwill Ambassador luckydog's Avatar
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    Default Re: Sub Woofer Construction Project

    is this your own design, or from some plans??

    years ago my buddy had 2 enclosures with 15" air suspension speakers for bass, I think retail was $400.00 each, when he cranked it up you could feel the bass right thru your body
    幸運わんわん Luckydog or Yukiwanwan in Japanese

  24. #13
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Hey LuckyDog! I love your new logo!

    This is my own design. The math was fairly straight forward as I had access to the speakers spec sheets. It did get a little complicated when I made the decision to conceal the drivers and add additional "features and power". I also wanted something "futuristic" and visually different from - "Oh, that's your sub huh" to "What is that?"

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  26. #14
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Here is the test fit of the blacked out separator chamber. I ran a wire through the front port and tested things at about 3 to 5 watts - Impressive... but the unit will need to be fully sealed to be complete.
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    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    This is the rear firing sub face... Blacked out and test fit.
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  30. #16
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    This is the addition of the bottom front firing port.

  31. #17
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    Well... I guess I should include a picture or something.
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  33. #18
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    A test fit of the upper cover and top firing ports - Chambers one and two sealed and firing. Even on a cement floor this is functioning well and exhibiting a lot of power. 28 and 54hz seem to flourish. A sweep from 20 to 240hz gives plenty of punch and power.

    There is a fair amount of buzzing. I have not completely secured the cabinet chamber and there is much more reinforcement to complete. I have to leave the upper lid unglued to complete the work.
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  35. #19
    Sandwich Shooter ShockSystem's Avatar
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    Default Sub Woofer Construction Project

    A sneak peek inside the second chamber containing a second, upward firing sub-woofer. The fit is working well and the seals are tight.

    I fired up the amp using sub out with my MP3 player attached... Wow! I will need to double the amount of screws I was going to use! This has got some punch!

    My math was off and I made a two inch adjustment on the upward firing chamber, with a massive power and performance improvement. I seated the woofer dividing chamber two inches lower than originally designed. The performance was noticeable even with the chamber divider just "tacked" in place.
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  37. #20
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    Default Sub Woofer Construction Project

    Here is the face cut for the upward firing section - This will project the sound toward the listener. I wanted a unique and futuristic look, so I picked a triangular port - It also forces a resonant reflection of sound through several frequencies (and aligns the dilithium crystals with the flux capacitor quite well).

    Shhh... yes, I was excited about my new hole saw Mrs. ShockSystem purchased for me and I stared a cut a 3in port on a "scrap line" and nearly made a lopsided project! So... don't tell anyone, OK - I can cover it up later.
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