The Best Speaker Box Design Available?

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Why are speaker cabinet hardware and your speaker box design program so important? Music and movie soundtracks are a lot like a nice mixed drink. The alcohol is there but sometimes it tastes so good you forget about it. Good speakers are similar.

Poor analogy maybe...

...but if you use the finest cabinet woods, speaker cabinet hardware, use all Thiele Small speaker driver data when building the enclosures...

instrument 2 loudspeaker, high fidelity stereo speakers

You are likely to end up with a successful speaker box design project.

Truly great speakers won't distract you from the plot or rhythm, the sounds and dynamics...

The Best DIY speaker box design will allow the sound to be created naturally without distortion, or sounding irritating and harsh.

A great DIY Speaker Cabinet Design can do this while also being affordable

The problem with most high end audio and video equipment is that it’s often very expensive.

But if you build your own speaker boxes and crossover circuits you can jump into some really great performance for very little money.

The reason this is so easy to do is that the markup, labor, and overhead for speaker manufacturers is extremely high. Building your own speaker box design nets a huge advantage over retail speakers.

DIY speaker box projects can range from ultra simple DIY computer speaker to cost no object DIY speakers.

These speaker kits can be assembled from a kit that includes all the necessary parts.

Speaker drivers, crossover components, wiring, and all are included.

These kits will give you a better value/performance ratio than retail speakers.

Get your own speaker box design plans available as home audio speaker kits on this site for free! Get the Instrument 2 speaker plans here! (floorstanding speaker shown above) Go to our Digital Audio Speakers and Speaker Plans page.

home sub woofer box design

The Instrument 2 DIY Speaker box Design Program is outlined as follows: (basic assembly instructions)

You will need to download the PDF plans from the previous link first. Then return here for instructions.

This article is to help you in setting up your Instrument 2 loudspeakers. It’s our experience with how to wrench the most from this great speaker system.

These make great stereo speakers or DIY home theater speakers for your home or studio. Be warned these are not light or small.

New upcoming articles on: Speaker Brackets and speaker box carpet.

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Instrument 2 DIY Speaker Box Plans and Cabinet Dimensions are as follows:

13” wide, 50” tall, 28” deep footprint, 32” deep front to back (with rake angle)

Weight Estimate will depend on the materials and drivers you use for the speaker build. My prototypes weighed 428 pounds each. I used concrete to fill the bottom cavity beneath the bass drivers and sand between the midrange cavity and bottom bass cavity; this probably made them heavier than if you did not use these materials.

Your decisions will change the weight depending on how much fill materials used, etc. I think it would be tough to get these to weigh less than 300 pounds as wood alone using no fill materials.

Instrument 2 DIY Speaker Cabinet Details –Using our DIY Speaker Box Design and making the Saw Cuts:

speaker box design cad drawing

I would encourage the use of Birch Plywood at least on the upper cabinet internals, braces, baffles, side panels etc. You could finish the box out it in MDF on all the outer layers and bottom bass cavity. This would save some money over an all birch ply enclosure.

I would also use Birch Plywood on the front baffle. As well as the outer side baffle skin that accepts the side mounted bass drivers.

Preparations and Cutting the cabinet pieces –DIY Speaker Box Design:

    • When cutting out the pieces make sure to keep a high degree of accuracy with the cuts.

    • Measure the pieces before and after your cuts.

    • Make notes on the boards about dimensions that may need some fine tuning.

    • Check the pieces for square also.

    • After cutting store them lying down on a dry and perfectly flat surface.

    • Need a ported or sealed cabinet speaker box calculator? Go to cabinet calculator for your speaker box design.

    Do not lay them on bare concrete as concrete holds a great deal of moisture which will wick right into the wood.

Cut the inner DIY speaker cabinet pieces a bit smaller than the speaker box plans call for (about 1/16th of an inch).

Cut the outer pieces a bit larger than the plans call for so that you can trim to size with a router cut. This will ensure that the cabinet will have smooth flowing lines as shown in the CAD drawings.

But it does depend on the accuracy of your inner layers and glue joints and glue thickness. Be as careful as you can with this process. Your efforts will be rewarded with a nice square and smooth cabinet that would hold together if you dropped it from the top of a three story building.

Use brads or dowels as necessary to hold parts in position while they dry.

I would encourage the use of a pressing table for assembly. These can be built fairly easily and will make the assembly and clamping job less time consuming.

General DIY Speaker Cabinet Assembly - Speaker Box Design Instructions:

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Return to: home speaker (home page) from speaker box-design

The links in this section may not be found on other pages on this site. These are deep links to more information from the DIY Speaker Box Design page.

Lay out the pieces and fit them together prior to gluing. Make marks on the front or back indicating which part is which and the sides that match up.

Make sure the angles at the tops, sides and bottom match as they should. Try to stack the entire speaker together on its side. Then take it back apart labeling the pieces as you disassemble.

Get familiar with how the pieces fit together, what they do and where they are placed.

This process may take a few hours but you will see how the speaker box design works as a system and may notice which parts need some more work and fine tuning.

To see our custom speaker plans go to our digital audio speaker page.

Gluing together your DIY Speaker Cabinet from the Speaker Box Plans:

Make sure to use P2000 construction adhesive.

This is polyurethane glue that forms an incredible bond between the layers of the cabinet. This stuff is incredible.

I don’t know of any better bonding glue for MDF, Birch Plywood or any type of wood. It gets rock hard too so if you mess up you can sand it down with an orbital sander. It also works great for filling edges, voids, nail holes, etc.

When you begin gluing your speaker cabinet together start with the inner front baffle alternate, back baffle, top baffle, bottom baffle, and one side baffle. Leave one side of the speaker box design completely open for final assembly, acoustic stuffing, wiring etc.

Use a router and sander to trim the pieces as you go along for correct fit. (After they dry)

To see our custom speaker plans go to our digital audio speaker page.

When you get to the final layer or outside shell of the DIY speaker boxes:

When pressing the parts together use boards under the clamp heads to spread out the pressure so that you don’t get any wavy surfaces.

Use a linoleum glue spreader to comb a nice thin layer of glue to one of the surfaces prior to sticking them together. Excess glue may not allow for a flat press of the surfaces. You can use the glue more liberally on the inner rib braces.

When gluing together the panels you will want to have the glue spread evenly and uniform in depth. Do not just squirt the glue out of the caulk gun tube in lines and stick the panels together. You will have voids and high points if you do this. The cabinet walls will not be flat.

Use the glue comb and cover the entire surface with a thin layer of glue. Trim the glue off the edges with a razor when it dries before joining any surfaces.

The back baffle is built as an assembly prior to beginning final construction. But the side panels and front baffle is a group of layers or sub assemblies. These must be fitted carefully and trimmed until they fit perfect. Take your time.

You may wish to assemble the outer layer one piece at a time (over the inner cabinet assembly) clamping in place and allowing glue to dry before fitting the next piece.

After drying, trim each piece with a flat router bit and apply the next section. This will ensure that the edges match up perfectly on the outer cabinet layer.

Place the front baffle 45 degree corner pieces last. These pieces sit against the main cavity body and the front baffle.

Don't want to build speakers and just want a small surround sound speakers system? - go here!

Construction Notes on Speaker Box Design:

Notice the ¾” inch gap (or void) on the speaker box design plans between the upper chamber and lower bass chamber. This can be filled with dried out sand or even concrete. Fill this void with sand before you place the last side panel into position and glue.

If you use concrete run a bunch of screws from bottom to top prior to filling the gap. This will lock the concrete and the braces together in multiple places. Use about 10 screws spaced out evenly. (Not overly critical) Fill the void with concrete after the screws are in place. If you fill with sand don’t use any screws.

The space between the upper and lower cavity serves to damp the pressures so that sympathetic pressures and vibrations are not carried into the rear of the speaker drivers diaphragms of one another.

The bottom (below the sub drivers) cabinet void could also be filled with some type of compound (lead, concrete, sand).

If you use sand I would fit an extra blank-solid-brace below the perforated one (at the bottom of cabinet) so that if you tip the speaker on its side during moving -you don’t have sand rolling into the back of the speaker cones.

Finishing touches

Fitting a solid piece beneath the perforated brace would seal the bottom chamber for a sand fill.

You could also fill this void with concrete for some added mass as I did. Make sure to give it a wavy inconsistent texture to help with standing waves.

The internal perforated cabinet braces act like the weapon silencer or “gun silencer”.

As sound pressure leaves one rib it flares out striking the next one. As it passes through multiple perforated ribs it encounters your cabinet stuffing (wool or fiberglass) and is deadened a bit each time it passes another one.

This method works very well for damping internal resonance (just like a gun silencer works).

The standing wave braces are placed at an angle between the perforated braces. These keep sound waves from bouncing from the front and back baffles freely.

Get these Speaker Plans for free! Go to our Digital Audio Speakers and Speaker Plans page.

The angle interrupts this bounce and encourages the pressure to travel up and down through the gun silencer style perforations.

Use the Best Speaker Cabinet Hardware you can afford. Use good binding Posts, speaker screws, hurricane nuts, metal wood inserts (for speaker screws) etc.

Need a wireless subwoofer? Keep the one you have and make it wireless.

Other Related Articles from - Speaker Box Design:

• Go Back to DIY Speaker Cabinet - Instrument 2 Setup Discussion

• Build Speakers - Using an HTPC to build the Ultimate Speaker

• Active VS Passive Crossovers - Build Speakers using Superior Science

• DIY Home Theater Design

• How to make a Speaker building Platform - Build a Speaker Box easier! Make your own Assembly Table

• Speaker Cabinet Hardware

• DIY Speaker Projects

• DIY Speaker Stands

• Acoustic Audio Speakers

• Best Speaker Wire

• Return to Home Speaker from: Speaker Box Design

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