Bluetooth Speaker Using Reclaimed Parts

Well, this was quite an intriguing project to tackle! At home, I always have a stash of components and parts salvaged from old machines and broken appliances. This time, I found a couple of speakers from a flat-screen TV, and I happened to need a new speaker for my workshop. After sketching out a few ideas, inspiration struck, and it was time to roll up my sleeves and get to work!

For this project, I recycled several components and materials. While I did have to spend a bit on some new items. Here’s a breakdown of what I used:

Recycled:

1. TV speakers (specific model: Samsung BN63-18441)
2. Power supply from a printer (any 24v supply works)(specific model: Canon Printer power supply: QM7-2846
3. Protective mesh from a motorcycle air filter
4. Scraps of wood

New:

1. 3D printed parts (about 500g of filament)
2. Bluetooth amplifier board (Sinilink XY-C50L or similar models, about $5)
3. A can of paint and a few sheets of sandpaper

After sketching out several ideas, I finally landed on the one that resonated with me the most. I wanted something with a distinctly retro vibe, but I had to work within the constraints of the components I already had. In the end, I opted for that oval shape, and I couldn’t be happier with the result.

In total, there were seven distinct pieces, all quite simple to print. The only one that required supports was the outer shell, but even that posed no difficulties. All parts were made with PLA. Here’s the list:

1. Outer shell (x1)
2. Back cover (x1)
3. Speaker frame (x2)
4. Speaker grille (x2)
5. Front internal support (right and left) (x2)
6. Rear internal support (right) (x1)
7. Rear internal support (left) (x1)

There isn’t much to explain for this step; it’s all about creating a few small wooden cones. I made mine by placing a piece of wood in a drill and shaping it with coarse sandpaper. The height can vary, but for this project, they measured 35mm tall with a diameter of 16mm.

I made the front cover using a wooden board I had around the house. First, I used a 3D-printed template and then copied it with a router. Here’s the template file

This will essentially be the space for the audio output: an outer frame, an inner mesh, and a grill that holds the mesh in place. There are two sets that will fit neatly into the spaces on the front cover.

With all the pieces ready, assembly can begin. As for the connections, there’s really not much to explain; the audio boards are already labeled with where the speaker ports and power input go. The only important thing is to check the voltage requirements to choose a suitable power source.

The assembly is quite intuitive, assuming that if someone wants to replicate it, they’ll be able to find similar components. In any case, you can always modify the design to suit your needs.

All set, I’m really happy with the final result! I know finding the exact same components to use the files I’ve shared here might be challenging, but I hope this at least serves as inspiration for anyone looking to create something similar.

Here’s a video showing part of the assembly process!

https://www.instagram.com/reel/DBwbNQDOmR9/?utm_source=ig_web_button_share_sheet&igsh=ZDNlZDc0MzIxNw==