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Construction of the Subwoofer Box

Necessary Materials:

· 4' x 8' sheet of ¾" MDF
· Two pieces of Plexiglass, ½" x 15" x 9"
· 4' x 8' sheet of ¼" MDF
· 6 tubes of Liquid Nails construction adhesive
· 1 tube of clear silicon caulk
· About 200 1 ¼" drywall screws
· Two linear yards of vinyl upholstery
· 2' x 4' sheet of 1/8" MDF
· Two cans of 3M aerosol adhesive
· 20 beige screw covers
· Four 12" Alpine Type-R Subwoofers
· Two 15" neon tube lamps
· 15' of 10 gauge wire
· One SPDT 12 Volt Relay

Necessary Tools:

· 7 ½" circular saw
· Jigsaw
· Electric drill
· Drill bits of various sizes
· Phillips screwdriver
· Caulk gun
· Scissors
· Stapler
· Tape measure/Ruler



Design criteria: The box must accomodate four subwoofers, and each subwoofer needs 1 cubic foot of air. Dimensions must be less than 15 inches high, 38 inches wide, and 28 inches deep. The back must be slanted to fit snugly behind the rear seats.
Each chamber houses two subwoofers, and will have a volume of 2 cubic feet. Design considerations would not allow for each subwoofer to have its own chamber (due to the dimsensions of the mounting surface: the base piece).

The cutouts for the subwoofers are made using a jigsaw, and the interior is spray-painted flat gray. The paint looks bad in this picture because it is still wet in some areas.
This is the box with the countersunk plexiglass frames installed. Half inch plexiglass will be used, so a 1/4 inch 'washer' is made and installed so that the plexiglass will be even with the 3/4 inch MDF on the outer surface.

The top is installed, and T-nuts will be used to mount the drivers.
The plexiglass has been installed along with the four 12" Alpine Type-R drivers, and the MTX 225HO amplifier. 10 guage speaker wire was used. The thin wires are for the two 15" neon tube light which are inside of the box.

The four subwoofers can be seen through the plexiglass. The plexiglass plates are screwed in and caulked with clear silicone caulk.
Panels were cut out of 1/4" MDF, which received beige vinyl upholstery that matches the interior of the SUV. These took 4 hours to measure and cut out correctly. The vinyl was attached using 3M aerosol adhesive and staples.

Here is the finished product. You are looking at about 45 hours of work. The whole thing contains about 200 drywall screws, 6 tubes of liquid nails, and weighs around 140 pounds. It is extremely loud as well (much louder than the landcruiser), and there are almost no audible vibrations of the vehicle (very clear bass). I designed and constructed every part of this, so I am very glad that it sounds good!