Advice Articles

Quick Guide for Sub Box Construction

Tools   Materials
  • Screwdriver
  • Calculator
  • Ruler
  • Pensil
  • Drill + Bit
  • Router or Jigsaw
 
  • 3/4" MDF or Particle-Board (MDF Recommended)
  • Coarse-pitched drywall screws
  • Wood Glue
  • Silicon Caulk
  • Terminal Cup
  • Speaker Wire
  1. Calculate the air space needed for the woofer. Multiply Length x Width x Height then divide by 1728 to calculate the cubic feet needed for the woofer. Refer to the woofer owner's manual for the recommended volume for the type of enclosure that you want to construct.
  2. Select the 3/4" material to be used. Choose MDF or Particle-Board.
  3. Make sure the boards have flat and even surfaces.
  4. Before you draw out the enclosure, don't forget to add 1 1/2" to each dimension ( L x W x H ) to compensate for 3/4" material used for the construction of your box.
  5. Before cutting the boards, follow all shop safety rules and wear protective eye wear.
  6. Use a table saw with a fence to avoid crooked cuts. This will provide a flat surface for the glue and boards to bond to.
  7. If the MDF or Particle Board comes in 4 by 8 foot sheets or bigger, then have someone help you in cutting it.
  8. After cutting smooth any rough edges with sandpaper.
  9. Test fit the assembly of the box.
  10. Pre-drill all screw holes that you will need to assemble the box.
  11. Use a coarse-pitched drywall screw for securing the box panels.
  12. Before final assembly run a bead of wood glue across all adjoining seams. This will ensure a strong bond for all pieces of the building material to adhere to.
  13. Screw and clamp the pieces together.
  14. Seal all interior seams with a silicon caulk to prevent any air leaks.
  15. Using the template that comes with the woofer, trace the outline on the front of the enclosure.
  16. If it is a ported enclosure, then trace the outline of the port on the desired location on the box.
  17. Trace the outline of the terminal cup on the rear of the box.
  18. Use a router or jigsaw to cut the holes for the driver, port (if needed) and terminal cup.
  19. Pre- Drill the 4 holes for the terminal cup using a 1/8" bit or smaller.
  20. Check the fit of the terminal cup.
  21. Install the gasket on the mounting flange of the terminal cup.
  22. Determine how much wire you will need to connect the terminal cup to the woofer and add 6 to 8 inches to allow you to install the woofer.
  23. Connect the wires to the terminal cup. Double check the polarity connection.
  24. Secure the terminal cup to the rear of the enclosure.
  25. Mark each screw hole for the cable clamps.
  26. Pre-Drill the screw holes for the cable clamps.
  27. Secure the cable clamps using 3/8" screws.
  28. Mark each hole for the woofer screws locations.
  29. Pre-Drill the mounting holes using a 1/8" bit or smaller.
  30. Install a gasket around the mounting flange of the woofer to prevent air leaks around the woofer.
  31. Connect the wires from the terminal cup to the woofer using a color-coded wire.
  32. Double check the polarity connections on the woofer.
  33. Position the woofer into the enclosure.
  34. Using wood screws, secure the woofer into the enclosure.
  35. Play music for 30 to 40 hours at a reasonable level to allow the woofer suspension to "Break - In." The woofer will perform much better once this process is complete!
  36. Then, enjoy your new subwoofer! Happy Bassing!

This article was last modified Aug 23, 2014

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