Stereo & Electronics - DIY box build v2

Enclosure ~ 6.0cuft net tuned to 32Hz , 77.5sq in port area .
Sub ~ Fi CarAudio BTL 18" d2 , fully optioned .


Bought (2) 3/4" MDF 4' x 8' sheet's for $45.00 . Started ripping my sheet's with a circular saw yesterday morning . I use a 8' straight edge clamped on as a guide . It didn't take me that long and the weather was great so I started assembling .

Tools I use is clamp's the length of box I am building , 90 degree corner clamp's , Woodglue , 1 5/8" length #6 coarse thread drywall screw's , drill fixture with a end to make the screw head sit in flush , hand block sander . And then your normal measuring devices .. speed square , tape measure , pencil etc .
Main powertool's I use is a circular saw to rip the MDF sheet's , Drill to apply the screw's and a jigsaw to cutout the sub hole . I usually have plenty of MDF left to use as a workbench sitting on wooden saw horse's I also made .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0209.jpg

Started with the Bottom and Back peice's , dryfitted .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0204.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0205.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0206.jpg

Removed the Back peice but left the 90 degree corner clamps as a guide .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0207.jpg

Then layed in a ample amount of woodglue . I like to lay down some plastic on the floor so that stuff does not get all over . Once the glue was laid in I set the Back peice in the 90 degree corner clamp's and putt on the big clamp's . I let it set a little bit but not to long where the glue is really setting . Then i start predrilling my holes and then finally applying the screw's .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0210.jpg

Next peice was the Left Side , same step's as before . Dryfitted / glued / clamped / screwed .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0211.jpg

Right Side

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0212.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0213.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0214.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0215.jpg

I let it set overnight and the next day I marked out where my Port peice was going to go . On the bottom I also marked it the same .
5" internal width port x 15.5" internal height = 77.5 sq in .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0216.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0217.jpg

Next I sanded the Front peice that make's up some of the port . Kind of rounded the edge . I plan to do this to all side's of the port opening .
Then I put in the Front peice for good .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0218.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0219.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0220.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0222.jpg

I am going to let it set overnight , this is as far as I went .

lookin good, i knocked out 2 boxes today

Started today by marking out all my 45's for the corner's . Tried to make a stand for the circular saw to cut them but I can not hold the thing steady , run the peice's through without them kicking back and hold the trigger at the same time lol.

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0224.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0226.jpg

I finally sourced someone with a table saw that would be willing to help me out and it was cake after that .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0227.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0229.jpg

Dryfitted to check how they sit , looked good but I still needed to cut them to height , chisel the glue off the floor of the box for them to sit flush .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0228.jpg

Also got around to cutting the port board to length and rounded the inside edge smooth .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0230.jpg

After cutting and scraping dried woodglue I put the box on it's side and layed in some glue where I had scraped off to make sure the box is sealed and then glued 2 of the 45's in.

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0235.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0236.jpg

Started sanding the port some , final sanding will commence later .

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0237.jpg

Thats a huge box, where is it going?

whats the purpose of the angled pieces in the corners?

whats the purpose of the angled pieces in the corners?

Support, Less flex

that a sub box or a coffin?

It's going in a '98 Acura Integra .

While they do kind of help support the wall's , it offer's no support to the middle . The idea is to rid the enclosure of any 90 degree corner's . Every turn will be 45 degree's beside's the port board , but I rounded the flat edge . More less for directional airflow .

The perfect sub box would be a round one with no corner's .

Some go with flared slot port , with kerf's cut and the MDF bent into a round shape and fiberglassed for strength . My next box will definately incorporate that technique but it makes the design more complex and for a given space the box would need to be even larger.

This box is about 8 cuft gross so while it is not small , it would just be a port compared to what's out there . I could have went alot bigger but I am putting more power than recommended for this sub so I am building more around the minimal reccomend internal volume for sub control.

Have not done alot to it , waiting for glue to dry is about it.

Put in one more 45 yesterday.

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0238.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0239.jpg

Installed the port board.

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0242.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0243.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0244.jpg

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0245.jpg

Last 45 installed.

http://i149.photobucket.com/albums/s55/cwsTA/DSCN0246.jpg