How to Build Your Own Bluetooth Boombox with Plywood

Boomboxes that were once famous and forgotten have now come back with a boom. Today, a boombox comes with latest technologies such as support for Bluetooth, USB and being rechargeable. If you’re a DIY handy person, you can easily build your own Bluetooth boombox with plywood.

Moreover, it’ll be fun and enjoyable. All you’ll need is some free time, the right materials, and some experience in assembling and soldering electronic components. Read on through this article on how to build your own boombox with Bluetooth technology using plywood.

Read Related Reading: Best Bluetooth Car Kit

Step 1- Preparing the Materials

In this guide, you’ll need a number of tools for the task to end successfully. Ensure you purchase the tools that are pointed out in this guide. Failure to have the right tools may render the end product not turning out how you’d expect it. Here’re the materials you’ll need.

  1. Speaker drivers- To start with, you’ll need some good speaker drivers. This is a set of speakers that comprise of tweeters, passive radiator and a woofer. When making a boombox, you will need 2 tweeters, 1 passive radiator and 1 woofer. You can go for more if you need a more powerful boombox. However, for portability, these ones would be enough.
  2. Passive crossovers- You will also require to get 2 passive crossovers. The crossover is used for separating low and high frequencies in audio. This will ensure that your boombox will deliver audio free from distortion even when playing your music at highest volume.
  3. Bluetooth adapter- Of course you’ll want to make a boombox that has support for Bluetooth. Thus, you need to get a Bluetooth adapter. You can find one online or from your local retail store.
  4. Battery pack- You should get a good battery pack for your boombox, preferably a 4-cell lithium type of better. This will allow for portability such that you can carry your boombox with you any time.
  5. Plywood- You’ll need thick plywood for the handle and body of your DIY boombox.
  6. AC adapter- You’ll need an AC adapter for stepping down AC to appropriate DC to charge or run your boombox.
  7. Other materials- Also get other materials for the job such as: *Wood glue, *Duct tape, *Masking tape, *Vernier caliper, *Pen/pencil and notebook, *Ruler, *Compass, *Hacksaw or miter, *Jigsaw, *Wood clamps, *Drill, *Knife, *Fabric such as denim

Upon gathering the necessary tools, you can start making your boombox.

Step 2- Taking Measurements for the Components

The next step will involve taking measurements for the boombox components. The measurements will be used when building the plywood boombox enclosure. Taking accurate measurements will ensure that the components fit properly and it will also ensure the body is tight. Preferably, take measurements using a Vernier caliper. Note down the measurements on a notebook using a pen or pencil. This is to ensure you don’t forget or confuse any measurements while building the casing.

Step 3- Marking the Plywood for the Boombox Components

Once you’ve all the exact measurements, start cutting the plywood according to those dimensions. Take a ruler and compass and use them to draw lines on your plywood. Ensure the lines you’re drawing are exact measurements of the components that is the speakers, woofer and the tweeters.

Step 4- Cutting the Plywood

Upon making all the required markings on the plywood, you can start cutting it with a hacksaw or miter. Cut carefully along the markings. To cut holes, you’ll use a jigsaw. Simply follow the layout and markings to cut out holes easily. You’ll also need to make holes at the back plywood for passing peripherals. While cutting, you may use wood clamps to hold the plywood. This way, you’ll cut more accurate holes with ease and take less time. Thus, you’ll avoid struggling and save time.

Step 5- Mounting the Speaker Components

Now that you’ve already cut holes, it’s time to start mounting the components. First mount them temporarily while marking the places you’ll make holes to mount the screws. Use a drill and make holes for the marked screw sections.

Apply some glue on the plywood cutouts. Only use high quality type of glue to ensure your boombox does not break easily. Then use appropriate wood glue for attaching plywood pieces to each other. Wood glue will bind the wooden casing together for a strong build.

Step 6- Decorating the Body

Upon attaching the plywood pieces together to make the boombox casing, you can decorate it for a stylish appearance. You can use a piece of cloth such as denim. Cut it and cover the wooden compartment. Use glue on the inner part of the cloth for it to stick properly. While covering the enclosure with the cloth or any other material you desire, ensure you have left space for speakers.

Use a sharp knife to cut out excess cloth and a circular pattern for the speaker holes. Allow for the fabric enclosure cover to dry completely. You can put it under the sun for faster drying and bonding on the plywood surface.

Step 7- Attaching a Handle

You can simply make a handle from wood or buy one. Make holes for the handle on the enclosure. Then screw the handle in place.

Step 8- Installing the Battery

Now it’s time to install the battery pack you bought. It should go towards the lower part, preferably at the back. Glue the battery in place to ensure it doesn’t move around or fall off in the boombox.

Step 9- Installing the Electronic Components

This step is extremely crucial. It will determine how your DIY boombox will work. Screw the all the components in place. Install the amp and AC adapter in place. Connect the speakers to the amp.  Then connect the amp board to the AC adapter. Also, connect the amp to the battery pack. This way, it can either run on the AC adapter or battery pack.

Also, connect the Bluetooth adapter to the amplifier board and to the AC adapter and battery pack too. Attach all the wires properly and solder them in place. Then test the boombox to check whether it’s functioning properly before closing the compartment. Once you test and it functions properly, close the compartment and enjoy your DIY boombox.

While building your own Bluetooth boombox with plywood may be fun, it’s not easy for everyone. Not every individual has the basic knowledge of assembling electronic components. You may also lack time to assemble it together. In case you’re not a DIY handy person, there’re many great boombox with Bluetooth you can get from the market to save you the challenge of assembling one on your own.

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