How to Build a Speaker Box

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How to Build a Speaker Box

How to Build a Speaker Box

You can use speaker boxes as a great way to install component subwoofers and speakers into an enclosure. Many subwoofers are sold as separate components, in order to install them in your car; however, you must first build an enclosure (speaker box). Speaker boxes are challenging to build, but can greatly enhance the sound of your car stereo. For those who are not up to the challenge, there are sub woofers and speakers that come pre-enclosed. You can also customize a box according to your component specifications.

What You Need to Create a Speaker Box

The best material to make a speaker box is ¾-inch medium density fiberboard. If money is no problem, you might be able to purchase exotic materials for far more, but for most people fiberboard is a great material to create a speaker box out of.

In addition to the fiberboard, you will need:

  • Jigsaw
  • Power drill
  • Down spiral bit
  • ¾-inch bit
  • Router
  • Sand paper
  • Razor blade
  • Spray glue
  • Screws
  • Silicone
  • Solder gun
  • Solder
  • Carpet

Figure out the Dimensions of Your Speaker

Practically all sub woofers and speakers that are sold as components without an enclosure come equipped with a template which includes the dimensions. This template makes it very easy to create an enclosure, because all the measurements are already made, you just need to transfer them to your fiberboard. If you don’t have the dimensions, try contacting the manufacturer online or make measurements on your own.

It is important to note that measurements are usually given as either exterior measurements or interior. If measurements are given as interior, you will need to take into consideration the width of the fiberboard (in this case ¾ inches).

Trace Your Patterns to the Fiberboard

Your speaker box will have six sides, plus a center divider. Use the template and a pencil to trace the fiberboard completely.

Cut Your Patters with a Jigsaw

Once the patterns are traced into the fiberboard, use a jigsaw to cut the patterns out. Make sure you purchase extra board in case you make an error with the jigsaw.

Once all the patterns are cut out, you will want to make traces of where the subwoofer speaker will be installed. Using the frame of the grille of the speaker, trace both the outer and inner portions of the subwoofer’s frame exactly where you would ultimately like to place the speakers.

Use a Router to Cut Out Holes

Use your router with a ¾ inch bit to route out the area of fiberboard between the inner and outer holes. Make sure that the speaker will be flush against the board. Once the holes are routed out, use sand paper to smooth out the holes. If your speaker box came with templates, look for the template for speaker connectors. If there is no template for creating speaker connector holes, create 2 inch circular holes, one on each side panel of the speaker box. Rout these holes and sand them smooth.

Assemble the Speaker Box

Now that all patterns have been cut out and all holes have been made, it is time to assemble the speaker box. Start assembling the box using screws, nuts and washers. Make sure to leave off the front of the box, this will be assembled later on. For best sound, you will want to create an airtight enclosure. Use silicone on all edges so that no air can escape.

Apply Carpet to the Box

You will need to apply carpet to the entire box via spray on glue. First, buy some carpet for your enclosure. You only need a few meters, but it should easily fit your box dimensions. Spray glue onto the box and onto the back of the carpet. Once the glue is applied, tightly stick the carpet to the box.

You will also need to apply carpet to the front panel without the speaker inside. Once the carpet is applied to the front panel, you can cut out the hole using your razor blade. One technique is to make a star pattern with your razor blade where your speaker’s grill would pass through and then smoothly cut away the carpet up to the hole’s edge. Make holes for the speaker connector as well using your razor blade.

Install Speaker Connectors

Install the speaker connectors and seal the edge with silicone so that no air escapes. Many professionals solder the wires of the sub woofer or speaker to the speaker connector and speaker wire. This is a good idea if your speakers will be in a position that is hard to get to. Soldering the speaker wire will ensure that the speaker stays connected. It is important to note that when installing the speakers, run the wire from the speaker connector through the hole in the front panel to the speaker. You will first attach the front panel to the box and then push the speaker into the hole.

Install the Speaker

Attach the front panel to the rest of the box. Once the front panel is attached, push the speaker into the box and attach the grill. Make sure that the installation is flush and air tight.

Images of Building a Speaker Box



  1. andrew said,

    on September 21st, 2011 at 11:36 pm

    Hellow… i am planning to assemble a speaker, but my problem is i dont have an idea for the wiring of the speaker, i want to assemble speaker that is compatible to my amplifier 50w.. what speaker i will buy,, can u give and guide for that.. thnx..

  2. Renron said,

    on December 21st, 2009 at 11:03 am

    IT’s a bad idea to use silicone for sealing the speaker boxes, the silicone give off vapors which can cause the driver surround to break down and rot. Acrylic stays malleable and is safer to use. Plus it accepts paint where most silicone caulk won’t.

  3. justin whitten said,

    on May 13th, 2009 at 5:56 am

    that looks real good