Though the size and shape may vary, basic speaker design has remained the same over the years.
Home theater systems require five (or more) speakers, plus a subwoofer, to fill each distinct channel of the 5.1 channel output from a digital audio source. While most receivers come with their own set of speakers, there may be instances when you prefer to make your own, either to better match the decor of the room or to have the feeling of creating something. This can be accomplished by assembling a pre-packaged speaker kit, or by acquiring the parts individually.
Instructions
1. Select the wood for what will comprise the outer enclosure of the speaker -- medium density fiberboard (MDF) or high-density particleboard at least 3/4 inches thick is preferred. Measure and cut the wood to the size you want the speaker to be, creating the front, back, top, bottom and sides of the enclosure, and cut the holes in the front panel for the woofer and tweeter, complete with intended countersinks for mounting, as well as a hole in the back panel for the terminal cup. Paint the wood a specific color (i.e. black) if you choose.
2. Assemble the various pieces of the speaker enclosure, using wood glue and/or inserting drywall screws to bond and hold the sections together, with clamps to hold them in place while the glue dries. Use a sander or a section of sandpaper to smooth out the edges and seams when finished. Also seal any remaining cracks to ensure optimal speaker performance.
3. Position the crossovers--the circuitry that splits the frequency spectrum into pieces to send to the different speaker drivers (tweeter, bass, etc.)--and use construction adhesive to secure them to the back (tweeter) and bottom (woofer) walls of the enclosure.
4. Drill holes in the front of the enclosure for the speaker drivers (woofer and tweeter), lining up where the screws will need to go when the drivers are mounted, and do the same for the hole in the rear panel for the terminal cup. Connect the positive and negative output wires from the crossover to the woofer, using a soldering iron or by attaching leads to the wires, and do the same for the tweeter, after determining which wires are for which purpose with the particular crossover you are using.
5. Connect the positive and negative input wires from the crossover to the terminal cup--the connection point where you will attach the speaker wires leading from the receiver. Mount and secure the terminal cup to the rear of the enclosure.
6. Insert a layer of acoustic stuffing into the driver holes of the enclosure, to cut down on vibrations and eliminate the hollowness within the enclosure that can cause sonic reflections. Mount the woofer and the tweeter drivers and secure them with the screws.
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