Created on 22.01.2012 15:07.
Updated on 27.02.2020 18:10.
Author: Marat Musin.
Cleaning up the garage once again, and stumbling upon an old suitcase, the idea was born to make a car subwoofer out of a suitcase. The advantages of such a solution are a finished exterior finish, plastic protective corners, a carrying handle (for example, if you need to bring the subwoofer home to free the trunk), and of course the original appearance.
Judging by the seal, I got hold of suitcase # 7, model 450, manufactured in 1972. Produced in the city of Troitsk.
The essence of the assembly is to implant a wooden subwoofer box inside the suitcase. According to rough estimates, the internal volume of the body should be about 15-20 liters. This volume is more than enough for most 8 “subwoofer speakers and some 10” ones. I chose an 8 “Polk Audio speaker model DB840 (favorite in the review of 8” subwoofers by Avtozvuk magazine for May 2009). The manufacturer recommends the optimal volume for a closed box of 9.9 liters.
The magazine “Autosound” recommends a minimum volume of 11.5 liters, and for the most even frequency response – 19 liters.
The first thing to start with is to remove the inner fabric lining and frame from the slats from the main part of the suitcase and measure the interior space for making the subwoofer box. We leave the lid intact, it is small in height, you cannot cut out a lot of volume from it.
According to the size obtained, we cut the panels for the subwoofer case. You can take both chipboard and plywood for the case. Material thickness 14–20 mm. I took plywood with a thickness of 14 mm, because half of the sheet is left from the previous project.
From the obtained panels on self-tapping screws and epoxy glue, we assemble the subwoofer box.
We try on the resulting box in a suitcase and temporarily fasten the panel on which the subwoofer speaker will be mounted.
In order for the lid of the suitcase to become, as it were, a single component with the subwoofer case, build up the panel on which the subwoofer speaker will be mounted. I needed 2 more plywood panels.
We mark the contour of the future hole for the subwoofer with a compass.
With a jigsaw, cut a hole in the front panel. It is unlikely that any industrial subwoofer will have such a thick front panel.
We take out the case from the suitcase, in order to cut a hole from one of the ends of the case for the acoustic terminal for quick connection and disconnection of the subwoofer to the amplifier.
Since the terminal is made of thin plastic, it will certainly rattle and make extraneous sounds. Therefore, we isolate the terminal from the internal volume of the subwoofer housing. To do this, we use a couple of plywood scraps left after cutting the hole for the speaker. We use one of the scraps as a spacer, and the second as a blank wall, in which a small hole will later be made for routing wires from the terminal to the subwoofer speaker.
We coat the ends of the subwoofer box with epoxy glue for sealing and greater strength.
And fasten the front panel of the subwoofer with self-tapping screws. We do not regret self-tapping screws. The sandwich of the front panel of 3 layers of plywood is also fastened with self-tapping screws over the entire area.
The internal volume, measured with water, was about 15 liters. The average value between those recommended by the Autosound magazine turned out.
We install the assembled plywood case of the subwoofer into the suitcase, in which we cut out the holes for the speaker and the terminal with a sharp knife.
And the very last step – we solder the wires to the terminal and the speaker, wash the surfaces of the suitcase, screw the terminal and the speaker itself into place.
This is how you can make an original car subwoofer in one weekend.