Prototype Speaker, Poster Board

Sometimes using cardboard, poster board or similar materials that are 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.

Painter tape

Hot glue gun

Glue sticks, (I went through about 5 of them)

Sharp razor cutter

A compass

A protractor

Three large sheets of poster board, Cardboard could also be used

Speaker

Speaker wire

Screws

Tape measure

Ruler

Following the measurements from the drawing, I marked out the speaker enclosure. The face of the speaker has a 5 degree slope, so I used my protractor and marked 5 degrees.

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 material 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 a hot glue gun and assembled the speaker enclosure. I left the one side to be the last piece which allowed me to seal all of the edges.

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.

Because the speaker is heavy I decided to double up the speaker area where the screws will be used to mount the speaker.

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 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.

Prototype Speaker with sound

Good sound, at low volumes. As you turn up the volume, the distortion becomes apparent and the board enclosure vibrates.