- 1). Cut the mdf to the desired specifications. The exact size will vary based on the size of the subwoofer, and the manufacturer's recommendations. But for this example you will need seven rectangles from the mdf: two for the front, one for the back, one for each side, one for the top and one for the and bottom.
- 2). Use a compass, or the template included with your subwoofer, to draw a circle on one of the squares with a pencil.
- 3). Glue the two front pieces together using plenty of wood glue. Make sure the piece with the circle is on top so you can see it for the next step.
- 4). Allow the glue to dry for 60 minutes. While it dries, you can work on the frame of the box.
- 5). Place a speaker terminal cup face up on top of one of your 12-inch squares. This will be the back of the subwoofer enclosure.
- 6). Use a pencil to trace an outline of the terminal cup onto the board. You'll need to trace at an angle because you don't want to use the outer lip, but the inner edge, as your outline.
- 7). Drill a hole on the inside edge of the tracing that is deep enough to accommodate your jigsaw blade.
- 8). Use the jigsaw to cut out the terminal cup tracing.
- 9). Squeeze silicone caulk around the cutout, and place your speaker terminal into the hole.
- 10
Make an "L" shape by gluing the top piece and bottom piece together. - 11
Repeat step 10 for the opposite side. - 12
Attach both "L" shapes together with glue to make a box (one upside down "L" and one right side up). Be sure to run a line of glue from top to bottom on any connection. - 13
Attach the back to the box with wood glue. Be sure to run a generous amount of glue all the way around the area the back of the sub enclosure will attach to. - 14
Glue the front of the box on by running a line of glue across each of the four open edges it will be attached to. - 15
Allow the glue to dry for 60 minutes. - 16
Caulk all of the seals inside the box with a hand-held bottle of caulk. Each seal should be covered with a generous amount of caulk. - 17
Pre-drill a hole in each of the four corners of the front of the subwoofer box. Make sure you are drilling through the front and the side piece it attaches to. - 18
Pre-drill a hole in each of the four corners of the rear of the subwoofer box. Make sure you are drilling through the rear and the side piece it attaches to - 19
Screw a 3/4 inch sheet metal screw into each of the eight holes you just pre-drilled. This will attach the front and back to both sides. - 20
Pre-drill a hole in all four corners of the top piece. Make sure you drill through the top and the side piece it attaches to. - 21
Pre-drill a hole in all four corners of the bottom piece. Make sure you drill through the bottom and the side piece it attaches to. - 22
Screw 3/4 inch sheet metal screws into the eight holes created on top and bottom of the box.
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