How to Build Custom Speaker Boxes
- 1). First measure your speakers to get both the diameter and the depth. You need enough room to house the entire speaker in the box. Then create a rough sketch of the box, using these dimensions.
- 2). Cut your particle board to size. You will want to cut the top and sides of the box first. Then install the speakers and cut and assemble the back if desired.
- 3). Assemble the top to the two sides first, using drywall screws and wood glue. Countersink the screws, and ensure that the box has a solid, tight fit.
- 4). Apply silicone caulking to the seams and let dry.
- 5). Find the correct size speaker ring for the diameter speakers you are going to use. Dry fit to ensure the rings fit. Then trace and cut an opening for the ring into your speaker box. Drill a hole about an inch inside the ring, then cut out the section using jig saw or rotary saw.
- 6). Install the speaker rings, then install your speakers. Connect your wiring and test to ensure the speakers don't slide or rattle. Fill the box with polyfiber or another fill to even out the sound. Then customize the box with upholstering. This also helps to distribute or "soften" the sound.