- 1). Draw a plan of your speaker box. If your speaker is 6 inches in diameter, the volume of your enclosure should be 0.3 to 0.4 cubic feet. If your speaker is 10 or 12 inches in diameter, build an enclosure with a volume of 1.0 to 1.5 cubic feet or 5.0 to 9.0 cubic feet, respectively. The depth of your enclosure should be 0.7 x width and the height of the enclosure should be 1.4 x width. The most common shapes for a speaker box are rectangular or triangular; you can pick which shape you build depending on the space you have available in your car.
- 2). Choose fiberboard to build your speaker box. Particleboard, often confused with fiberboard, isn't a great option because it doesn't stand up to the elements faced when used inside a vehicle. Plywood is another viable option.
- 3). Use your drawing as a guide to draw the speaker box designs onto your fiberboard. Cut each individual section using a jigsaw.
- 4). Cut out the speaker hole in your speaker box. The hole, created on the front piece, should be the same size as the diameter of your speaker. Using a pencil, outline the edge of the speaker, where you'll make your cuts, centered on the front panel. You can cut it out using your jigsaw.
- 5). Apply a bead of carpenter's glue to the edge of your pieces and assemble them together to form the speaker box you designed in your drawing. Secure the pieces using wood screws. Drill one screw every 6 inches along the joints of your speaker box.
- 6). Fill a caulking gun with sealant and apply that sealant to the interior joints of the speaker box. This sealant helps your speaker box become airtight, providing the best quality sound for your speaker.
- 7). Secure the baffle board with screws on the front panel to hold the speaker in place. You might also consider installing a grill to help better protect the speaker cone.
- 8). Cover three adjacent inside walls in your speaker box with polyfill, available at your local craft store. This helps reduce mid-bass resonances. Spray a spray adhesive to these walls, then just smash the polyfill on those walls to get it to stick.
- 9). Drill a hole into the bottom of the speaker box for your speaker cables to run out of the speaker box.
- 10
Finish your speaker box with the material of your choice. You can spray your spray adhesive on the box and cover it with fabric, or you can paint the outside of the box to give it a finished look.
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