SubWoofer Enclosure

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Introduction: One fine day, while watching movie on TV I realized, there is always a room for a large Sub-Woofer to reproduce those effects, which sometimes is difficult for a smaller cone speaker to produce. In short, if I may ever want to play loud music/movie or host next house party, I would need a beast which can control the crowd and create an ambiance.

Project Objective: To make a Sub-Woofer that can compliment existing sound system and reproduce special effects at greater power levels. This Sub-Woofer should meet minimum following criteria :-

  • Should have tight and accurate bass at power levels beyond 100Watts.
  • Since the above point can be achieved using large Sub-Woofer (typically 12″~18″), I would like to keep the enclosure small AND sealed for tight and accurate bass. I already have few 12″ Subs that can be used for this project :-)
  • Should be able to run using existing LM4780 DIY KIT.
  • Yes, an active Low pass filter needs to be added (ready-made v/s DIY, I am still confused)
  • Should look aesthetically good when placed below wall mounted TV.

Project Cost: This Project cost me approximately Rs.1800 (for enclosure, paint job & T-Nuts) + 3 Weekends (Please refer to “Project Cost” and “Pricing” section on “Terms and Condition” section on sidebar for complete information)

BOM :-

  • A 12″ Sub-woofer of good make. You can also use a smaller or larger Woofer. If you are NOT using 12″, you need to recalculate the enclosure size and cutting dimensions of plywood.
  • 1/3 sheet of 18mm or thicker, 100% Marine Plywood.
  • 8 T-Nuts with 6mm Allen bolts.
  • Cutting Jigs for making circular holes for front baffle (Please refer to “My Tools” section)
  • Basic woodworking tools to cut plywood, drill and joinery.
  • High quality wood putty or Automobile grade grey putty.
  • Setup for spray paint/primer (you can use brush/roller if you don’t have spray-paint setup.
  • 1 x push steel terminal connector for output
  • Foam for sealing

The first thing that need to be finalized for this project is the size of the Sub-Woofer. All the above calculations in BOM is as per a typical 12″ Sub-Woofer i.e. 1.0 Cu.Ft3 Sealed box. If you are NOT using a 12″, please recalculate your box dimensions by using one of the calculator from Google search or from this link:- http://www.hometheatershack.com/forums/enclosure-volume-calculator/

For this Project, I am going to create a pictorial with texts and WIP pics. This would be one of the best way to describe the build process and would help me to update this page faster. For a start, below is the WIP pics, which will be updated soon with build steps.

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Before any of you give me any feedback about the above scrolling pics, let me tell you that I am equally annoyed with the scroll and its misalignment. This is temporary before I find a better solution.

Current status: Completed (Working on build steps guide)

Here are some pics of finished project:-

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