Prototype Speaker, Cardboard

Using cardboard is low in cost can provide a prototype to be made so that the form fit and function can be study or reviewed prior to spend lots of money on wood products.

In this case I wanted to build a single speaker full range speaker box to visualize the speaker and determine if I wanted to build a pair made out of costly MDF wood.
I knew it was not going to sound perfect, but it did allow me to work out how much of the sheet of wood I would need, how the construction steps would need to be ordered to build it and it provided good sound quality enough to make my decision on whether to build a pair for a new speaker project.

Duct Tape to tape all edges

Sharp razor cutter

A compass

A protractor

A large Cardboard box

Speaker

Speaker wire

Screws

Tape measure

Yard stick ruler

Following the measurements from the drawing of the speaker design, I marked out the speaker enclosure onto the cardboard box.

The face of the speaker has a 5 degree slope on the face.

I used my protractor and marked 5 degrees and then measured out the needed length.

I used a compass to measure and then mark the circle for the speaker cut out. Using the tape measure I measured out each length and then marked where all the cuts are needed for each piece.

Using a very sharp, new razor blade I carefully cut out each piece.

NOTE: have a box under your cardboard to protect the floor or desk you are cutting on from damage. Warning: razors are sharp, retract the blade when not in use. Have an adult make these cuts for you if you are not old enough to use a razor.

Using duct tape I assembled the speaker enclosure. I left the one side to be the last piece which allowed me to seal all of the edges internally. Be sure to seal all the edges that need to be sealed. I put the plan cardboard facing out so that no print or marking was shown.

If you want to be able to take apart the enclosure to use as a pattern, you can use painters tape to assemble the enclosure which will allow to peel the tape off and then you can put the pieces on the wood to trace out the enclosure.

To make the speaker area stronger I did a few layers of duct tape so the screws had more to dig into.

I poked a screw driver and ran my speaker wire through.

Using wire strippers I removed the insulation from both ends of the speaker wire. I attached the black wire to the negative and the blue wire to the positive of the speaker and used four screws to mount the speaker.

Once the speaker enclosure was complete, I placed the speaker in the area that allowed me to see if it would be small enough for the room.

It was nice to be able to look at the form fit and function of a new speaker design. It was built in less than an hour. It was strong enough to hold the speaker. With a small full range speaker, it sounded great, even though it is only a 5 watt speaker. The next step would be to listen to some music and try it out.

Cardboard Speaker

Good sound, at low volumes. As you turn up the volume, the distortion becomes apparent and the cardboard enclosure vibrates. But at a good listening level the speaker performs nicely.