Building a Woofer Box is not as easy as it sounds. This article will guide you on building a Woofer box in minute detail. We will divide the process into several steps.
The first step would be to have all the Tools and Materials needed:
- 3/4" Medium Density Fiberboard(MDF)
- Carpenter's glue
- Electric Drill
- 2" Drywall Screws
- 1/2" and 3/4" Panhead Sheet Metal Screws
- Silicon Caulk
- Non-hardening Rope Caulk
- Table Saw
Once you get all these together we would move on to the second step of building a woofer box, Designing the Enclosure:
To design the box you must first determine the dimensions for your box. First determine the depth of your box, measure the depth of your woofer, add 2 inches to it. This would be the minimum depth of your box. Then determine the height of the box, measure the diameter of the woofer and add 4 inches to it, that would be your height, otherwise check the mounting template included in your woofer's manual. Do the same what you did for the height to determine the width of the box. This will determine the external dimensions for your woofer box. Now we have to determine the internal dimensions and volume of the box.
If you are using 3/4" fiberboard then you should take out 1-1/2"(2x3/4"=1-1/2") from your external dimensions. For the internal volume use this formula: Internal Height x Internal Width x Internal Depth = Internal Volume.
Now get started on building your woofer box by measuring and cutting the main pieces of MDF for the front, sides, back and top of the box, using a table saw, preferably a table saw with a carbide tipped blade. Once the pieces are cut, mark the cutout for the woofer using a compass on a front piece. Now make a hole near the inside edge of the circle traced using the electric drill, large enough for our table saw blade to fit in. Use the table saw to cut the circle out. After the woofer cutout is complete, we use the same procedures for cutting out a rectangular space in the back of the box for the terminal cup. As now the back and front pieces are complete, now put everything together. The sides should be fastened to the front and back first, and the top and bottom last. As the board used can split, drill holes for the screws in each piece before putting them together. Put a good quantity of carpenter's glue between the pieces, as eventually the glue would be holding the pieces together. Fasten the pieces together using the drill and the 2" drywall screws. Now it’s time to put the woofer in, but wait till the glue dries out, then mark the screw holes for the woofer and drill them. Put silicon on all the internal seals of the box then after that dries out, connect the woofer wires with the terminal, then use silicone caulk to seal the woofer in place. Now fasten it using 3/4" sheet metal screws.
Finally our woofer box is complete.