Project: DaJe is going to make an acrylic subwoofer

[DaJe]

My Dremel should be delivered by Wednesday, so I can finally start making projects around here.




I've been given a sound proof piece of acrylic

http://codeinsurrection.com/pics/computer/mod/PICT7610.JPG


Here's my crrent subwoofer

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7624.JPG


I'll need to get a bigger bit for my drill, to make a hole like this for the speaker to go into.

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7625.JPG


I can take this tube out and use it as an air vent in the new one. Unless I can find an acrylic tube somewhere. Or I could just make a hole.

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7627.JPG


And I could either use the feet it already has, or get some acrylic ones. Maybed some lighted ones.

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7630.JPG


And here's the speaker itself.

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7631.JPG


I made some cardboard cutouts of each side of the subwoofer, to make sure I'd have enough acrylic. I removed a little bit from two of the pieces, to compensate for the thickness of the acrylic.

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7622.JPG


And of course, my cat always has to be a part of everything

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT7621.JPG




I was thinking of putting some lights inside of it, perhaps some sound sensative cathodes. Though I have heard some bad things about those cold cathodes. I'm also not sure how I would hook up power to the lights either. I don't think I'd want to hook it directly into the power for the subwoofer. The subwoofer plugs into the back of one of my speakers. Though maybe it would work. Does anyone have any ideas on how I could hook up the lights?

[DaJe]

I've got the basic shape of it made in SketchUp. Next I'm going to draw it all out out paper, and use that as a template to make sure I cut all the pieces right.




http://codeinsurrection.com/pics/computer/mod/subwoofer/subwoofersmall.png


http://codeinsurrection.com/pics/computer/mod/subwoofer/subwoofersmall2.png




I might get some blue LED acrylic feet for it. What I was thinking of doing, is having a molex conenctor inside to hook all the lights up to, and then wire it into my computer somehow. I'll work it out by the time it comes to do it.

[.Maleficus.]

If you're putting lights in it, are you going to 'frost' the acrylic first, or leave it completely transparent? I personally would sand it a little with some high grit sandpaper (well not too high, 600 to 800 should suffice) just to give some slight opacity. Looks better IMO.

LED feet would be cool.

The molex idea is pretty good, if you got some split loom or mesh sleeving, you could sleeve it all as one wire (speaker-in and light wire) and it wouldn't look too bad.

I hope you get the Dremel soon so this can really take off!

[DaJe]

Are you saying to run the wires for the lights, and the wire for the speaker, sperately but still sheathed together, and both plugging in to the speaker? I just don't want the changing current in the speaker effecting any of the lights. I'm not sure if that would happen though.

[.Maleficus.]

Yep, that's what I'm saying. I don't think you'd need to worry about that, but if you are really skeptical, you could just test it quick enough.

[DaJe]

Well, If I do go for the molex, do you know where I could buy some molex connectors? Could I just use copper wire and a molex connector to make this work?

[.Maleficus.]

I'd see if there is an old power supply somewhere you can hack some off from. Actually, you could (if you don't mind doing this) cut off the connector from your PSU, extend the wires using some copper wire (take the cut off molex with you when you buy the wire and buy the same thickness as the PSU wire) and sleeve it up. Shouldn't be too hard if you have either heat-shrink tubing or electrical tape to connect the extensions with the PSU and the other end with the molex connector.

[DaJe]

I actually do have an old power supply or two that I'm not currently using. My current power supply also has modular cabling, so if I wanted to I could take one of the unused cables and harvest it.


Now, what have you guys heard about those sound reactive cold cathodes? I've heard stories of things overheating and melting. Are they safe?

[sirkillalot617]

I like the idea good luck with that.

Oh and ur cat looks exactly the same as mine.

http://s96.photobucket.com/albums/l168/sirkillalot617/?action=view&current=catSmall.jpg

[DaJe]

But how could we have the same cat



Unless...

http://codeinsurrection.com/pics/oceanthumb.jpg (http://codeinsurrection.com/pics/oceanfull.jpg)

[sirkillalot617]

lol u never know with cats.

[.Maleficus.]

About the sound reactive cathodes melting: I don't think they'll melt any faster than regular cold cathodes. I have some white ones in my rig right now, and one of them is almost burnt out, looks like one end is almost on fire :eek:. I don't keep them plugged in unless I go to a LAN or have friends over, but CCFLs will always have a risk of burning out and/or melting.

[DaJe]

Well I wasn't worried about sound cathodes, but all cathodes in general. I'm not sure if I want to use something that has the risk of melting >_>

[.Maleficus.]

In that case, take a look at Lazer LEDs (http://www.xoxide.com/lazerled.html). They just might be right up your alley. Pretty bright, cover a large area, won't start you on fire (hopefully..)

[DaJe]

I'll probably get the cathodes anyway, since I wanted something sound reactive. Any color suggestions?


And any idea where I can find some small ones, rather than a 12 or 15 inch one? I have 6 3/4" of room.



Nevermind that.


I found some 4 inch cathodes in all colors

http://www.frozencpu.com/cat/l3/g6/c75/s130/list/p1/Lighting-Cold_Cathode_Lighting-4_Single_CCFL-Page1.html


And a sound activation addon that I can hook up any cathode to

http://www.frozencpu.com/products/2997/lit-37/Sound_Activation_Cold_Cathode_Addon_w_Blue_LEDs.ht ml?tl=g6c79s128

[SgtM]

You could do the LED thing since it's safer, and fabricate your own sound sensitive device. I'm not that great with circuits, but I'm sure someone on here can help you build that.

[DaJe]

I was thinking about hooking up LEDs to a sound device. And I can buy a sound device seperately, with a 4 pin molex connector. So if I could hook up the LEDs via molex, that would be an easy thing to do.

[DaJe]

The Dremel arrives tomorrow. I've cleaned and prepared the acrylic, and I taped on a template. I really hope everything has a straight edge to it.



http://codeinsurrection.com/pics/computer/mod/subwoofer/acrylicpaper.jpg

[rendermandan]

so your going to cut out all those pieces with a dremel?

[DaJe]

Yes, that's what I'm going to do. I also ordered some diamond cutting wheels to use when I cut some steel, not sure when they'll arrive though.

[rendermandan]

ohh, thats alot of straight cutting to be done with a dremel. Its going to take you for hours, and based on the pics I'm assuming its pretty thick. It can be done, but it will be hard to keep the cuts in plex straight for that thick of material.

If you have access to a table saw, that would be your best bet!!

[DaJe]

It's 1/4" thick. And there's no way it's going to take me multiple hours to cut it all.

[rendermandan]

I guess it is thinner than I thought. Looked like 3/8 to 1/2" to me.
I'm just trying to help. You want you cuts to be straight. Otherwise they won't be air tight and you sound pressure will escape thru the cracks. Because you have a port, you want all your pressure to be direct out of that port. If it were a sealed enclousre, it would be a must to have tight joints. Especially since your working with Plexi. Wood glue is used on wood and fills in the joints and seals the joint. An idea around this with plexi would be to use clear silicone on the inside of the joints. But you would still see it. that is unless you plan to frost it.

Like I said, Just trying to help. :)

[DaJe]

The sides are straight, just a little rough. I'll have to grind them a little. Perhaps I will frost the entire thing. Then I wouldn't need to worry about it being shiny. But also, you wouldn't see the inside components, but would still see the lights.



I took a scrap piece of acrylic and sanded both sides and all directions. And then after I took these pictures I sanded the edges as well, and it blends well with the rest of it.


http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77052.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77062.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77072.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77082.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77092.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77102.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77112.jpg



We really need a thumbnail mod so I don't have to crop and re-size all of my pictures >_>

I usually take them in a resolution of 1600x1200

[rendermandan]

to do the frosting, try using some 800 grit wet dry paper under water. That won't leave sanding marks.

[DaJe]

Will do. Though even if marks do happen, it'll be alright. And the marks are't as visable as they appear in the pictures. Especially since I cleaned it now.

[itsjustacompaq]

to tell you the truth, unless you file those pieces within an inch of their life, you will never get them to fully seal, making the sub sound like crap. you should try another piece on a table saw with a decent fence installed on it. water jet is another option, but not many people have access to it.
i have built a few boxes, and i am trying to get a job as a car audio installer over the summer. the only way you'l get those to seal is to caulk the living daylights out of them, making it not look good at all. im not trying to knock your idea, but the dremel is the last thing you should have thought about for making an air-tight box. i will say this: once you have it done with the lights in it though, it will look completely badass.
edit: for the frosting, i reccomend a vibrating palm sander with 800 grit paper if you have access to one. the strokes on it are so small you cant easily see them.

[DaJe]

You haven't even seen the pieces I cut though.

[Drac998]

We really need a thumbnail mod so I don't have to crop and re-size all of my pictures >_>

I usually take them in a resolution of 1600x1200


The software that came with your digi cam should have an option in tools for Resizing, for both individual and batch pics.

[LiTHiUM0XiD3]

lolz no ya dont.... imageshack has the option........ use image shack... to host ya pics.........

[DaJe]

**** that. I'll just stick to using my own server and Photoshop.

[b4i7]

when sanding...sand one side..... then when lighting it...it will fill a lot better color wise

[DaJe]

I had a similar idea to that. I was thinking of sanding one side with a fine grit sandpaper, and then sanding the other with the Dremel, to make it rough. and then having the rough side on the inside.

I tried sanding it with an 800 grit, and that just wasn't enough for me. So then I tried it with a 320 grit, and it's the look I'm going for. I'll cut a few more test pieces and try a few different sanding combinations.

[rendermandan]

how about some pics of the pieces you've cut for the box? I'm curious to see how your edges turned out.

[DaJe]

The cuts went through it straight

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77302.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77332.jpg



And it's straight along the whole length of it too

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77362.jpg



It's just a little rough, and I can just sand/grind it a little with the Dremel, to smooth it out.

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77382.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT77392.jpg

[DaJe]

Now that I've been given the idea of frosting it, I actually don't want it to be clear. I tried it with an 800 grit at first, like suggested, but it was still too clear for me. A 320 grit looks good though




On the left is unsanded acrylic, the middle is sanded on both sides with an 800 grit sandpaper, the right piece is sanded on both sides with a 320 grit.


http://codeinsurrection.com/pics/computer/mod/subwoofer/acrylicsand.jpg

[tybrenis]

You might want to try a slightly higher grit combined with wetsanding for a true frosted look - right now you can still see scratch marks and everything, which look a bit sloppy.

[.Maleficus.]

Great idea ty, +rep.

[DaJe]

That is wet sanded. And I don't want a higher grit. I want it to have a low clarity.

[tybrenis]

Hmm, still. You can have low clarity w/out scratch marks. If you're satisfied, thats all that matters. It just seems like it could use a bit more.

[DaJe]

Actually, I think I sanded this piece wet and dry. Ah well. Anyways, you can't really see the marks as well when just looking at it. It's the picture that makes them seem visable.

[DaJe]

Here are some pictures! Click the thumbnails to see the full image.



Everything came out alright

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7740thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7740.JPG)


The edges are straight, just a little rough is all. But they're mostly smooth now, since I sanded them with the Dremel and then some sand paper.

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7742thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7742.JPG) http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7743thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7743.JPG)


Here's where I did all the work

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7745thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7745.JPG)


Bits of crap everywhere now

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7746thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7746.JPG)http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7747thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7747.JPG) http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7748thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7748.JPG)


Some random stuff. I don't even remember why I took this picture

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7749thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7749.JPG)


The tool I did this all with

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7750thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7750.JPG)


Always important to wear eye protection

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7751thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7751.JPG)


A mask can help too

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7752thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7752.JPG)


The different attachments I used with the Dremel. I broke two cutting wheels while doing this >_>

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7753thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7753.JPG) http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7755thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7755.JPG)


A bunch of boxes piled up. From all my computer parts and from the materials and tools I used for this. Though my 8800GTX box and Dremel box are not there.

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7756thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7756.JPG)


I do all work on computers in that room too, so I have things like this motherboard, just laying around.

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7757thumb.jpg (http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT7757.JPG)

[DaJe]

I now have all pieces frosted.


http://codeinsurrection.com/pics/computer/mod/subwoofer/frosted.jpg

[danthegeek]

lookin damn good. The frosting looks awesome. KEEP GOING, YOU DONT NEED SLEEP!!!

+rep :alien:

[DaJe]

Well I need some super glue to attach some nuts to some brackets. And I kind of want to wait for the cathodes to arrive, so I can figure out how I'm going to hook them up so they have power. I got super glue on my mouth >_>


I could probably cut these holes for now though

http://codeinsurrection.com/pics/computer/mod/subwoofer/subwooferholes.jpg


As for the cathodes, depending on the connectors they have, I may harvest a male and female molex from a fan, and then mount the connector for the cathodes on inside on the side using some scrap acrylic, so I can just plug a molex into the side of the subwoofer. Then I can just use some copper wire to make it long enough to plug into my computer.

[DaJe]

I started cutting out the holes in one of the pieces.



For the big hole, i first made a rough hole using the biggest drill bit I had laying around.

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78032.jpg


This drill

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78062.jpg


This bit

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78092.jpg


It was rough, and off center, but it was just a starting point

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78052.jpg


I then put a sanding drum on my Dremel

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78142.jpg


And grinded it until it was the right size

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78152.jpg


It may be a little uneven, but that's okay

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78162.jpg


Because once the speaker goes in, you don't even see it

http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78172.jpg

[DaJe]

I have now finished working on that one piece. I cut all the holes, threaded the screws, attached the speaker, created an air vent, and attached the vent tube.




http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78182.jpg


http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78212.jpg


http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78222.jpg


http://codeinsurrection.com/pics/computer/mod/subwoofer/worklog/PICT78252.jpg

[rendermandan]

thats a pretty small sub. What size is it?

[chaksq]

Computer subs aren't that big. I have one about the same size hooked up to my computer.

[rendermandan]

Computer subs aren't that big. I have one about the same size hooked up to my computer.

Um, I believe mine is a 6.5" high excursion sub in band pass enclosure.. From Logitech. its the Logitech Z-5450 system. I have seen them up to 10" though. But that was just a sealed enclosure.

[tybrenis]

My computer sub is a beast - it's about 10" x 10" x 15" and way heavy.

[DaJe]

My cathodes arrived! Now coems the thinking part. I need to design a way to hook it all up.

[DaJe]

Son Of A ****ing****! I just caused a ****ing short. Nothing was damaged. But still, it was a short.

[DaJe]

Here are some pictures showing what the lights will look like inside. They won't be in the exact positions they're in now though, and there won't be wires everywhere. Also, they won't be on at all times. They'll pulsate to the music. Not only that, but the red and blue will pulsate seperately. I just wanted to see how the light looked through the frosted acrylic.


http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT78952.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT78972.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT79002.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT79012.jpg

http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT79022.jpg




Now, as for the work on the subwoofer. I've applied some clear silicone sealant on the inside edges, to ensure it's airtight. Once that cures, I'll scape off the excess. Then I'll wash the whole thing and sand a few more areas. I'll also grind down a few spots that stick out a little. I'll also have to wire up a power cable for the lights, and perhaps put some switches on it.

[GT40_GearHead]

i don't want to be the one with the bad news but that thing you call air vent and air tube its actually a bas reflex port ! and the length and diameter of it are VERY VERY IMPORTANT because a certain length/diameter will AMPLIFY a certain wave length (frequency)

the bottom line, get your Dremel and cut the horrible grill in front of the hole and build a decent bas reflex port !

[DaJe]

Yes, I know the grill looks bad, oh well, I can't make it look better >_> Anyways, it's the same length and diameter as it was in the original subwoofer. The tube in the original subwoofer also had a sort of "grill" as well. I'm sure lights inside will probably affect the sound as well. I'll take my chances and see how it turns out.

[DaJe]

It sounds fine so far. I did a test with it.




Anyways, I'm re-doing things with solder now, rather than just twisting the wires and using electrical tape.





http://codeinsurrection.com/pics/computer/mod/subwoofer/PICT79102.jpg

[XcOM]

don't forget your heat shrink.

And BTW, removing the grill will reduce air restance, and increase your bass output.

I built a bass for a friends car, made from Chipboard, 6x9, and a PRINGLES TUBE!!!!!!!

PS. And lots of caulk!

[Maz]

Xcom do you live by Sheffield plastics?

its actualy pretty easy to calculate the size of the tube by frequency.
just look here (http://en.wikipedia.org/wiki/Loudspeaker)

You want the tube to resonate so pick up a physics book or google it to get the resonance in a closed tube. the actual resonance of your speakers you can usually find from the manufacturer.

[DaJe]

I think I forgot to mention this, but I used sound proof acrylic to make this.

[tybrenis]

Hate to break it to you... but "sound proof" acrylic is a load of crap. It's just acrylic at a certain thickness that it sort of "soundproofs" things. ...not really.

[mwdaley]

I think the acrylic sub looks great! The lights add a nice touch. I hope they don't interfere with the sound.

Forgive me for saying so, but don't post that solder picture for what a solder joint should look like...maybe you can heatshrink those suckers.

[DaJe]

I know it's a terrible looking joint, but it works, and is now hidden. I think my main problem was too much burned flux on the soldering iron. And this acrylic is something my brother had laying around. A window from his studio foam. But I suppose I'll trust you on this. It doesn't even matter anyway. The sound proof has no effect on this subwoofer.

[Eclecticos]

When do we get an update on this one?

Looks Kewl. . :up: :up:

[DaJe]

I finished it, I just never posted final pictures or anything. I'll get on that though.