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Glass boxes for subwoofers: how they do it in America. Encyclopedia of radio electronics and electrical engineering

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Encyclopedia of radio electronics and electrical engineering / Speakers

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Installers often aim to make the subwoofer the centerpiece of the system. Especially when it comes to a demo car or competitive installation. True, this is not always possible, but everyone tries, because the subwoofer box is the element of the audio complex on which you can experiment and create masterpieces of installation art. The founding fathers of car audio have long and actively used fiberglass for the construction of the subwoofer component and achieve impressive results. We asked the well-known American studio Competition Soundworks to share their experience. They were just getting ready for the next competition, but they did not refuse to fix the main milestones of the boxing construction on film, as well as provide the pictures with appropriate comments.

1. The first and, perhaps, the simplest operation: a box was assembled from a half-inch MDF, which will become the basis of the entire structure.

Glass boxes for subwoofers: how they do it in America

2. The American installers at Competition Soundworks used the parameters specified by the speaker manufacturer to determine the cabinet volume. When determining its shape, they proceeded from the features of the luggage compartment of the car (in this case, the Volkswagen Jetta).

Glass boxes for subwoofers: how they do it in America

For greater strength, the seams and corners are treated with silicone sealant.

Glass boxes for subwoofers: how they do it in America

3. Since the case is supposed to be "charged" with two 12" heads, 4 mounting rings will be needed for a secure fit, which are cut from approximately 14" x 14" MDF sheets.

4. You can cut off the outer corners with a simple hacksaw, but then you will need a tool popular with American installers - a manual router. With its help, the first of four rings of a perfectly round shape is cut out. The ring can then be used as a template: it is nailed (usually with a "gun") with small nails to three sheets of MDF, after which the remaining rings are sawn out.

Glass boxes for subwoofers: how they do it in America

5. The outer and inner surfaces of the three bonded rings are ground on a stationary grinder, after which the rings are separated.

6. The outer corners of the two rings are rounded on a stationary grinder.

7. The rings are ready, now you need to fix them in the box.

8-10. The two rings are attached to the drawer with temporary brackets, which are small strips of MDF, using nails and wood glue. The main thing here is to accurately measure everything so that the rings are at the same distance from each other and from the walls of the case. In the attachment points, marks are made in case of unforeseen "undocking".

Glass boxes for subwoofers: how they do it in America

11. At this stage, you will need additional fasteners (all the same MDF plates, only installed vertically) to make the rings turn on top of each other. All fasteners are removed only at the final stage of the process.

Glass boxes for subwoofers: how they do it in America

12. The radio fabric is pulled over the open part of the box over the rings. The two remaining rings (with rounded corners up) are nailed with small nails to those already installed in the case. The fabric thus appears between the rings. This will require a fairly significant tension of the fabric, since it will then have to be coated with fiberglass (polyester resin).

13. The fabric is stapled to the body (every centimeter and a half). During this process, the fabric must be stretched.

Glass boxes for subwoofers: how they do it in America

14. Excess fabric is cut off with a regular blade.

Glass boxes for subwoofers: how they do it in America

15-16. The fabric is coated (with a brush) with a layer of polyester resin. This should be done in a well ventilated area. At a positive temperature, the resin dries out in 5-10 minutes (if in the sun, then even faster).

Glass boxes for subwoofers: how they do it in America

17-18. After complete drying of the first layer of fiberglass, a second layer is applied from a mixture of resin, volume filler and hardener. Dries 20 minutes.

Glass boxes for subwoofers: how they do it in America

19-20. Glazier time. The dry surface is covered with another layer of polyester resin, and then fiberglass is applied to the adhesive surface. The operation is repeated until a layer is formed from 1 to 1,5 centimeters thick.

Glass boxes for subwoofers: how they do it in America

21-22. After the fiberglass dries (this will take about half a day), the surface is again treated with volume filler to avoid unevenness. Next, the entire surface is carefully sanded. If there is a desire, then the radio fabric covering the speakers can be removed. Although many installers leave it on so that the subwoofer is better protected from dust.

Glass boxes for subwoofers: how they do it in America

Author: A. Krasner, 12 Volt; Publication: 12voltsmagazine.com

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