| Box BuildingEach type of sub requires it's own | | | | to minimize gaps between the box and the tube. |
| type of box. If a sub is installed in a box larger or | | | | A couple wood braces can be added for screwing |
| smaller than what is supposed to, it will sound | | | | the port top the box. Seal the gaps using a |
| distorted/bad and could be destroyed. Boxes can | | | | proper sealant (Evo Stick or even silicone can be |
| be built in many shapes, but it is important that | | | | used).BracingBoxes that are more than a foot in |
| the box volume is calculated accurately to achieve | | | | width or length or height, should be braced so |
| maximum performance.MaterialsA box MUST be | | | | that the box becomes more sturdy. This can be |
| very sturdy. Most common building materials are | | | | accomplished with a piece of wood maybe 3 or 4 |
| 5/8" or thicker particle board or medium density | | | | inches wide across the box). It is a good idea to |
| fiberboard. If building a box with Plexiglas, do not | | | | put wood blocks on the corners for |
| use anything less that 1/2 inch thick. A common | | | | reinforcement. Always consider that blocks, |
| material used to mold complex shaped boxes is | | | | braces, neon lights, etc. inside a box take up |
| fiberglass, but it is very hard to work with, and | | | | space and should be accounted for when |
| require several layers for a smooth finish.Gluing, | | | | calculating internal volume.Damping/FillingDamping |
| SealingGlue should be used at all joints to fill any | | | | increases subwoofer efficiency by dissipating |
| spaces. Any spaces will degrade the performance | | | | some energy that affects the sub, particularly the |
| of your subs, not to mention the annoying noise | | | | voice coil. It is advisable to put damping material |
| air makes when being pushed out of a small hole. | | | | inside a box. Pillow polyfill and fiberglass insulation |
| On applying the glue, let it cure for at least 24 | | | | are common, though polyfill is a lot easier on your |
| hours before mounting the subs. This is a | | | | skin. Polyfill also "tricks" a sub into thinking it is in a |
| precautionary mesure to protect the rubbers | | | | bigger box. Play around with different amounts of |
| used to make the subs from the high fumes that | | | | polyfill until you get the desired results.Making it |
| some manufacturers glue products have.Holding | | | | look professionalMake the box surface free from |
| Joints TogetherIn connecting box joints, it is best | | | | holes and spaces by adding wood fill. If you decide |
| to screw the joints every four inches or so using | | | | to paint the box, then you should apply primer |
| 2" - 2-1/2" screws. Pre-drill about 3/4" deep, so | | | | first. Carpet or Vinyl padding is the best covering |
| that screws do not split the wood at the edges, | | | | to use since they easily cover any outer |
| especially when working with particle | | | | blemishes on teh box and give the box a 'smooth' |
| bashboard.Should I have a Box for Each Sub?It is | | | | outlook. Be carefull when cutting the vinyl or |
| advised to have a separate chamber for each | | | | carpet since such cutters tend to be very sharp. |
| sub. Even though not necessary, here are two | | | | Cut a piece of carpet (or vinyl) big enough to |
| reasons why such a directive should be taken: | | | | cover the whole box. Apply adhesive to both box |
| First, if one of the subs blows, then the volume | | | | and carpet (EvoStick works great). Wait about a |
| of the box will be "twice" as big for the one | | | | minute and place the fabric over the wood. For |
| remaining working sub. This could cause problems | | | | the best fit, stretch the fabric when applying it. |
| and even damage the other sub. The second | | | | The fabric should wrap around and end in a place |
| reason is bracing. Building a box with a divider in | | | | of the box that will not be seen. Do one side at a |
| the middle will make the box more rigid.PortsPorts | | | | time, cutting excess carpet. If possible, add |
| must be built into your box design to channel out | | | | staples preferabke heavy duty staples that can |
| the air made by the sub's vibrations. If a | | | | penetrate the box, to hold the fabric at the ends. |
| pre-made port is not available, the most common | | | | NOTE: Do not cover each panel of the box |
| material is PVC . PVC is very rigid, comes in | | | | before mounting it together since it would be |
| different diameters. Cut the tubing at the desired | | | | impossible to find any 'leaks' that may exist in the |
| length. Consider the volume the port takes up | | | | box design much less fill these leaks.Get more |
| when calculating the box volume. Cut a hole in the | | | | Auto/Car Audio and Video help. |
| box. Make sure the hole is as perfect as possible | | | | |