Bronco Subwoofer Box Build - Double Baffle, 45's, Custom Insert Work

[mklett33 10+ year member]

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:



Made all my cuts using a table saw





Did some work on the front baffles:



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

Click to read more...

 

[mklett33 10+ year member]

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







I also added a roundover to my port.



Baffle looks much better:



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.

 

[mklett33 10+ year member]

Painted all the inside pieces black:



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:



Started the assembly process using clamps and wood glue:





Box is really taking shape now:









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.

 

[mklett33 10+ year member]

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



Applied body filler using a smart spreader:





Sanded and looking smooth



Look how perfect that transition is:

 

[CSCStang]

Very nice work man.

 

[mklett33 10+ year member]

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:









Now it fits perfectly:





Wrapped the insert with vinyl:

 

[mklett33 10+ year member]

Now I am going to add a logo. Im using speedfoam from Ultimate Audio Fabrication for an embossed look.

 

[mklett33 10+ year member]

Now the box is complete!













Packed up for loading into a cardboard box. //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 

[mklett33 10+ year member]

Finally, here is a video showing the whole process //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 

[NatesMazda]

can i please get alpine type r 10 inch d2 plans!

 

[CSCStang]

can i please get alpine type r 10 inch d2 plans!

I can hook you up with free plans. Pm me

 

[bradl79 10+ year member]

You all always do an awesome job, love watching ur work

 

[Jeffdachef 5,000+ posts]

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© 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.

 

[NatesMazda]

kk thanks

 

[mklett33 10+ year member]

I can hook you up with free plans. Pm me

Thread jack much?