PDA

View Full Version : Bronco Subwoofer Box Build - Double Baffle, 45's, Custom Insert Work



mklett33
03-09-2015, 10:09 PM
Recently built this subwoofer enclosure for 2 12's in a Bronco. I wanted to share the build pics with you all.

Started with some wood cut down from the local store:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2067_zpsvsmwz8ff.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2067_zpsvsmwz8ff.jpg.html)

Made all my cuts using a table saw

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2069_zps9oebwucb.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2069_zps9oebwucb.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2070_zpstwgmt2zd.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2070_zpstwgmt2zd.jpg.html)

Did some work on the front baffles:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2074_zpssqwkdyky.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2074_zpssqwkdyky.jpg.html)

Used a Fukuda router tool to make a perfectly rectangular port:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2076_zpsfhqaszsw.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2076_zpsfhqaszsw.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2077_zps9hrvmmu6.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2077_zps9hrvmmu6.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2081_zpspwbklpb3.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2081_zpspwbklpb3.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2087_zps1lbtk1uu.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2087_zps1lbtk1uu.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2089_zps32bmlelb.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2089_zps32bmlelb.jpg.html)

mklett33
03-09-2015, 10:12 PM
http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2090_zpshyj5asak.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2090_zpshyj5asak.jpg.html)

Next I used one of my mini bits from my Mobile Solutions set to add a small roundover:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2094_zpsdeuonhfq.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2094_zpsdeuonhfq.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2095_zpshjosbjmz.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2095_zpshjosbjmz.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2097_zpsj6lps35b.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2097_zpsj6lps35b.jpg.html)

I also added a roundover to my port.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2098_zpsmpjfrmzm.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2098_zpsmpjfrmzm.jpg.html)

Baffle looks much better:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2100_zps5sibeacq.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2100_zps5sibeacq.jpg.html)

Here is a sick trick, go extra deep on your roundover on the port entrance, it will leave a hard edge to cut carpet on later.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2101_zpsy7x2fmkj.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2101_zpsy7x2fmkj.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2102_zps6dftayfk.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2102_zps6dftayfk.jpg.html)

mklett33
03-09-2015, 10:15 PM
Painted all the inside pieces black:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2103_zpssxssgnty.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2103_zpssxssgnty.jpg.html)

Used this sick huge rabbeting bit I got from Mobile Solutions to cut this notch in the corner of the side pieces, this is also for carpet wrapping:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2104_zpsuicwpqdy.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2104_zpsuicwpqdy.jpg.html)

Started the assembly process using clamps and wood glue:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2105_zpsanwppvk6.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2105_zpsanwppvk6.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2106_zpsdpucta8m.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2106_zpsdpucta8m.jpg.html)

Box is really taking shape now:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2109_zpsmxgsi9h3.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2109_zpsmxgsi9h3.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2117_zps9etd4deq.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2117_zps9etd4deq.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2122_zpsbobl51dn.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2122_zpsbobl51dn.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2130_zps3cdkrn57.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2130_zps3cdkrn57.jpg.html)

Now we need to add a bit of custom flair. Lets add this shape here for highlighting an embossed logo. Im using a smart template.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2131_zps3rfyxuzt.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2131_zps3rfyxuzt.jpg.html)

mklett33
03-09-2015, 10:18 PM
http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2132_zpspvtsffvg.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2132_zpspvtsffvg.jpg.html)

Copied the shape to 1/2 MDF and protected it with TESA tape:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2136_zpswrzz0gvy.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2136_zpswrzz0gvy.jpg.html)

Applied body filler using a smart spreader:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2138_zps9toeoeaw.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2138_zps9toeoeaw.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2140_zpsxjbpjx4k.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2140_zpsxjbpjx4k.jpg.html)

Sanded and looking smooth

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2155_zpswmi3httz.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2155_zpswmi3httz.jpg.html)

Look how perfect that transition is:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2156_zpsmrc2nelr.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2156_zpsmrc2nelr.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2157_zpsqp73ykdc.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2157_zpsqp73ykdc.jpg.html)

CSCStang
03-09-2015, 10:22 PM
Very nice work man.

mklett33
03-09-2015, 10:23 PM
Now we need to make our insert fit after vinyl and carpet is applied. This means we need to remove material from the wood of the piece otherwise it wont press fit. I use the material compensation set from Mobile Solutions:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2159_zpsaoytsvgb.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2159_zpsaoytsvgb.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2162_zps75oovdum.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2162_zps75oovdum.jpg.html)


http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2165_zpswofauyjy.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2165_zpswofauyjy.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2164_zpsw8eoseln.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2164_zpsw8eoseln.jpg.html)

Now it fits perfectly:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2163_zpssrbzaf77.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2163_zpssrbzaf77.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2158_zpsxgwqs9xc.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2158_zpsxgwqs9xc.jpg.html)

Wrapped the insert with vinyl:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2166_zpsuk1zispa.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2166_zpsuk1zispa.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2167_zps6hcwguvw.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2167_zps6hcwguvw.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2171_zps3tkfi8g8.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2171_zps3tkfi8g8.jpg.html)

mklett33
03-09-2015, 10:25 PM
Now I am going to add a logo. Im using speedfoam from Ultimate Audio Fabrication for an embossed look.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2176_zpsujgzhryi.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2176_zpsujgzhryi.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2178_zpsphkyhquy.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2178_zpsphkyhquy.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2182_zpswy34gt2v.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2182_zpswy34gt2v.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2185_zpsfjyz6g1h.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2185_zpsfjyz6g1h.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2186_zpsrc9rg9yc.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2186_zpsrc9rg9yc.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2196_zpsgpavu7nr.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2196_zpsgpavu7nr.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2201_zps8fhwgibl.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2201_zps8fhwgibl.jpg.html)

mklett33
03-09-2015, 10:27 PM
Now the box is complete!

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2196_zpsgpavu7nr.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2196_zpsgpavu7nr.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2201_zps8fhwgibl.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2201_zps8fhwgibl.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2228_zpsprygvhyv.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2228_zpsprygvhyv.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2236_zps5nzbzmja.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2236_zps5nzbzmja.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2237_zpspv0zqpbd.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2237_zpspv0zqpbd.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2240_zpsbobz2u64.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2240_zpsbobz2u64.jpg.html)

Packed up for loading into a cardboard box. :)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/DSC_2244_zpsqlwpmrbc.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/DSC_2244_zpsqlwpmrbc.jpg.html)

mklett33
03-09-2015, 10:38 PM
Finally, here is a video showing the whole process :)


http://www.youtube.com/watch?v=xExMUDtRhFI

NatesMazda
03-09-2015, 10:46 PM
can i please get alpine type r 10 inch d2 plans!

CSCStang
03-09-2015, 10:51 PM
can i please get alpine type r 10 inch d2 plans!

I can hook you up with free plans. Pm me

bradl79
03-09-2015, 10:51 PM
You all always do an awesome job, love watching ur work

Jeffdachef
03-09-2015, 10:56 PM
can i please get alpine type r 10 inch d2 plans!

1.25 cubic feet at 32hz Make the port length of the last port wall(C) shorter( or take it off completely) if you want higher tuning. Make sure you add mini 45 degree angle cuts for wave guides and sand down all the sharp edges.

http://img.photobucket.com/albums/v340/Creatre/Box%20Plans/125cubes32hz21sqin4qf.png

NatesMazda
03-09-2015, 10:58 PM
kk thanks

mklett33
03-09-2015, 11:18 PM
I can hook you up with free plans. Pm me

Thread jack much?

CSCStang
03-09-2015, 11:25 PM
Thread jack much?

No man. Mean no disrespect whatsoever. Apologies.

mklett33
03-12-2015, 06:18 PM
You all always do an awesome job, love watching ur work

Thank you.

massivespl
03-12-2015, 08:31 PM
Awesome work! Very nice detail

MrFoca
03-12-2015, 08:45 PM
What's that box tuned at ? Port looks short

mklett33
03-13-2015, 12:02 AM
.

Im sorry, didn't mean to come off that way, long day at work. Just like to keep the conversation on topic but I guess I will look at it as free bumps. :fro:

Thanks for the kind words

mklett33
03-13-2015, 12:04 AM
Awesome work! Very nice detail

Thank you