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Making a subwoofer box isn't as tough as most people
would think. Just as long
as
you know what size to make the box or can calculate the dimensions based
on a given internal volume. By the time I'd built this box I'd already
made a few that turned out really nicely. Before I built the box
I sketched everything to scale on graph paper in order to serve as a guide.
Pencil marks are a lot easier to fix than a wrong cut. Unfortunately
I had to cut the wood using a jigsaw since I didn't have access to a table
saw. I did manage to make perfectly straight cuts by making a fence
with some C-clamps and a carpenter's square.
To mount the plexiglass windows, I first cut out
their shape in the wood, then used a router to make a 3/8" "shelf" to support
the plexi. I went through 4 jigsaw blades cutting the plexiglass,
the fact that I used 3/4" probably had something to do with that.
To secure the plexi, I used liquid nails and clear tub/tile caulk to seal
for any leaks. I also secured the inside seams of the box with the
clear caulk just to be safe.
To add to the volume "seen" by the subwoofers I
used poly-fill stuffing. Certain places sell this stuff for $8 bucks
a pound. However, Wal-Mart sells the exact same stuff to be used
as teddy bear stuffing for about $2 bucks for all I needed. I used
a staple gun to secure the stuffing to the interior of the box so my subs
could be viewed. Although it's tough to see in the above pic, I used
some leftover mesh from my grilles to place on top of the plexi to protect
from scratches and to match my amplifiers.