Does anyone know good websites with box building instructions? I am looking to build a custom box and would like to know what size, what materials to use, do you screw, nail ,or glue pieces together, how do you seal it etc...

 

But they give great tips, and have quite a library of speaker building software.
http://www.speakerbuilding.com

 

Get a program that calculates the enclosure size that is needed to make your box.
The difficulty of the box will be determined by what kind of box you build, sealed is the easiest and the most forgiving of error.
Material: 3/4" MDF (medium density fiberboard), I would use thin nails with glue or a wide gap screw with glue (MDF is like real fine particle board, so it can fall apart). Then use a silicon caulk to seal from the inside.
Tips: Save the back piece(the side without the holes cut for the speakers) for last cause then you can seal the inside easier by sticking your arm in the hole for the sub, but make sure you've already sealed everything else. Also, do not get MDF wet!! It absorbs water and then expands...I had the misforture of finding this out.

 

Glue the mdf box together. Then use 2 inch wood screws every two inches to screw it together. I sealed the inside of mine as I went along gluing.

 

What kind of glue??

 

http://jlaudio.com/home/tutorials/index.html

 

any good wood glue will be great.. I don't remember the brand I usually use, but it's pretty thick and doesn't run.. it'll form a bead on the edge of the wood where it oozes out- almost like caulk. 1.. this keeps the glue where it needs to be, and 2.. it does the second "bead" seal on the inside of the box.

if you're going for a really tight enclosure, paint the box with sanding sealer or clear polyurethane after you get done building it. MDF is very porous, and this will help to seal it better. (also will help protect it from water, should your trunk happen to be open in a downpour)

for screws, I use 2 1/2 or 3" drywall screws.. but be sure to predrill and countersink the holes.. I ruined my first box because I didn't do it.. all the others I've predrilled and countersunk, and it makes a world of difference in the end quality..

here are a couple pics of my box on my website (if the server is up) that you can take a look at..

http://24.1.29.190/blehm/pics/car_st...nstruction.jpg

http://24.1.29.190/blehm/pics/car_st...nus_carpet.jpg

note the runny glue on the back panel... this was back when I still used Elmer's wood glue.. runny stuff!

 

You're such a show-off

 

lol so tell me, how do you guys cut the wood? when i was making a box for my computer i used a regular circular saw and man i couldn't get two peices the same size.

chris

 

A table saw, and a rotozip.( ok the Rotozip isn't needed, but it helps!) Only way you can use a circular saw is to use a straight edge (2x4?) clamped down to the MDF to guide the circular saw. Most Rent-All places carry a table saw though, and it helps a lot.

 

Home Depot gave me 2 "free" cuts i needed to do it to make it fit into my max. I inquired how much more each cut would cost and they told me it was .25 per cut. so i just thought quickly and had them cut it for me in 5 min. their tolerances for error are like .05" on thier cuts. saved me a lot of trouble cutting it myself...and the box looks great! I used bathroom caulk (silicon) cause it was cheaper per tube. for the carpet use the spray glue...i cant remember the name but that sucker is strong. make sure the seals of silicon have no bubbles! happy building!


POWERED BY HONDA....I EAT EM FOR BREAKFAST

 

3M 77 spray adhesive

 

Use a good polyurethane glue like titebond. This stuff will expand to fill any gaps and make the whole silicon step unnecessary. The polyurethane glue won't wear out over the years like liquid nails, another highly reccomended speaker enclosure glue. Sealing the box is also a good idea. Their are many paints that can do this. I have in the past used the 'rubberized undercoating' material. This is also frequently used in tree trimming and it's pretty cheap. you can get it and the glue at Wal Mart or you can get this stuff by itself at an auto parts store. Just spray the inside of the box and it will be air tight. The spray adhesive mentioned above is good for adhering carpet.