DIY Mini Bluetooth Speaker (BoombeAt :)

Hey Guys! It's my second instructable. I got great response at my previous BBox tutorial so I really thankful to all of you. If you really like this project than please VOTE for me and help me to make a winner :)

MEET BoombeAt :)

BoombeAt is a DIY ultra-portable wireless speaker with impressive bass and portable design. Featuring high performance audio performance with dual full-range stereo 35mm speaker and a passive driver. This versatile speaker allows you to stay connected with your friend with long lasting battery life. BoombeAt provides upto 3 days battery backup at continuous music playback with a single charge.

WIRELESS FREEDOM WITH ALL DEVICE

Pair with any Bluetooth compatible device including smartphones, MP3 players, tablets and computers. Play or pause music, change track, volume up/down, all without touching your phone.

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In this instructable I'm going to show you how I made this portable Bluetooth speaker. So take your tools, We are going to build a great weekend project.

PROJECT INSPIRATION

I made this project inspired from ASCAS's DIY Supercharged Bluetooth Speaker(v2.0). He is an awesome guy and formally known for his various DIY Speaker projects. I just gave my own touch on his project in this instructable. I really thankful to him :)

Speces & Features:

• 3w*2 High Efficiency Amplifier( Class D)
• Bluetooth 2.1 With SBS Decoding Audio Performance
• Dual 3w Full-Range Speaker With Passive Radiator(4ohm-35mm)
• Long Lasting 4000mAh Battery(2800mAh Li-po+1200mAh Li-ion) [2days playback]
• Aux Ready
• Command Buttons
• Micro USB Charging

Here's the Sound test Video

Time to select some proper parts for BT Speaker. These parts I'm using to build my BT speaker. You can use this parts. But if you find better parts then use those parts for better performance.

• Bluetooth Module [$4]
• 35mm Speakers (3w*2) [$1.5]
• PAM8403 Stereo Amplifier (3w*2-4ohm) [$1.5]
• Li-po and Li-ion Batteries (4000mAh) [Recycled]
• Micro USB Charging Module With Battery Protection [$2]
• Acrylic Sheet (4mm thick)
• On/Off Slide Switch [3*Recycled]
• 470uF Capacitor [1*Recycled]
• 10k Resistor [4*Local store]

Tools & Equipment:

• Rotary Tool
• Screw Driver set
• Glue Gun
• Soldering iron
• Baby Hacksaw
• Sandpaper
• Superglue
• Cutter
• Masking Tape

Measure the acrylic sheet and mark it, then cut the layout. Again cut the main layout into two pieces. One for rear and another for front panel of BT speaker.

Here's the dimensions (14*5*4cm)

Take measurement of speaker's diameter and note down it. Draw holes exactly same size as speaker's diameter by using ruler and compass. Don't make bigger holes than speaker's diameter then speaker won't get fit on them.

This is the most hardest part of this instructables. Take your rotary tool we'll start of by drilling a large hole inside the circular marking then sand of the excess plastic by using your sanding drum tip. Do the same process for passive radiator. But still I don't have any rotary tool that's why i used only hacksaw and sandpaper for the cut the holes.

At first we'll give a temporary support between front & rear panels then we'll wrap both the panels by using masking tape, Next attach upper & lower panels with it. Then Soften the acrylic by heating it with a gas stove. after soften the acrylic quickly and carefully bend the acrylic. My neighbour's a little guy helped me a lot during bending the side panels. when i was holding the side panels at front of candle then he was blowing air at candle's flam through the pen straw.

We're going to mount the speakers and passive radiator. we'll start by adding a thin layer of superglue around the edge of the speaker's hole. Once we add our layer of glue, flip the front panel, position it, and rest it on top of our speaker and hold it in place for several minutes. Again we'll repeat the same process for other speaker. After doing so, we'll use the same method to seal passive radiator. next apply a thin layer of hot glue around both the speakers and passive radiator to ensure that they are 100% airtight.

I started off by sanding the lower panel, it necessary to remove the glossy finish, then superglue can join both the panels permanently. Next apply great amount of superglue on the edges of front panel and quickly position it to lower panel then hold it for couple of minutes. Finally add plenty of hot glue at the joint of two panels.

Simply make hole corresponding the same size of your command buttons, also you can use your old recycled buttons. I'm using these buttons which I got from an old speaker. Next use a small piece of PCB board and solder all the buttons. Then add good amount of hot glue to fixed the buttons permanently.

Similarly add slide switch to the back panel.

Simply make holes for switch by using your rotary tools, after doing this sand the holes perfectly, then install the switches and apply some amount of hot glue on the corner side of switches. you can see that I attached two switches in one place. you can also do this for better result.

I'm using BK8000L Bluetooth module which provides high quality sound and compatibility. It has SBC audio decoding performance. Here is a problem while using it with PAM8403 amplifier board due the common GND, will have current noise. But how I used the PAM8403 amp board in this project. Don't worry, i'm unveiling the real story. I used two batteries in the place of one battery. one for amp board and another for BT module. when we'll use two batteries then we'll get differential GND and these won't effect each other. Thus it helps to eliminate sound noise and we can still work with PAM8403 amp without any problem.

I made an extension board to attach BT module for durability.I strongly recommended this cause if you use BT module without extension board then wires might not be solder well or comes out frequently.

In this part we're going to install and connect the speakers, amplifier and Bluetooth module. At first we'll connect the wire to speakers VCC(+) and GND(-) carefully. Then we connect these wires to amplifier's L(Left channel) ,G(GND), R(Right channel). Next we just connect wire to VCC(+) and GND(-) of amp board. After that we'll connect wire between amplifier's L G R to BT module L G R connection [Note: BT Module has two negative output(LN and RN). So connect Both negative terminals for balanced stereo performance]. Then solder wire on functional buttons.

here I'm using two batteries one for amp board and another for BT module. But you can easily say that how i'll charge these two batteries. after some research I got an idea. I'm using a slide switch to charge these two batteries separately. we can use this method for charging two batteries one by one without facing any problem. I recommend to use a charging module with battery protection inbuilt but you can use mobile battery, that already has a inbuilt protection board.

Mount all the command buttons with 10k resistors on a PCB board, then solder wire.

Now its time to make the complete circuit. You've to connect all the components carefully and exactly same as the circuit diagram showing.

Apply hot glue on battery and quickly attach it to the back panel.

After make complete circuit, Now we'll attach the back panel. first apply superglue around the edges of back panel and quickly position it, then still hold it for few minutes. after that apply enough amount of hot glue to make it 100% airtight.

First solder command button's wire, then seal the upper panel by using superglue. Next press still for few minutes.

At first cover speakers and passive radiator by masking tape. Use your rotary tool to grind off the sharp edges. Next sand the surface until you get the flat and smooth surface. It can take some time, but it necessary to fill the gapes.

Paint your BT speaker with your favourite colours. I'm using here two colours matte black and Yellow. you choose yours. I also gave vertical and horizontal pattern for more attractive look. After painting it looks exactly same as my expectation.

Add rubber feet to reduce vibration while place it to any flat surface. Customize your BT speaker with your creative ideas.

I really enjoyed a lot while I'm building this project. Make Your own BT speaker and show it to your friends, May be they also like to make their own and that's how we DIY maker can expand our community. Thanks for watching this. Again I'm requesting you guy's please vote me. Don't forget to follow me for upcoming projects.