1st Boombox Project - The Madeleine

[Gordy]

I decided that I wanted to build a Bluetooth boom box. Yes another boom box. But, I wanted this one to be a little different than most and not be portable. If it were to sit on a shelf and never move that would be just fine. So to build on proven design, I decided to use the Overnight Sensation platform. The goal was to build a single cabinet that was split into two enclosures that would house the BT module, amp and only have a plug for power. I did not want to be too adventurous and use veneer as this is my first build, so I chose to build the cabinet out of red oak.

I ordered all the parts as well as sourced some via eBay and Altex Electronics. I think the end result will be simple and elegant. The cabinet was assembled using glue and dowels. There is not a single screw or nail. I have never used just dowels and glue before and this was learning experience I will post some pics of the build so far and if anyone has an questions just let me know.

[Gordy]

Re: 1st Boombox Project - The Madeleine

Here are thecross overs. I am still missing a 6.8 cap but that should be here in a few days

[kenny_k]

Re: 1st Boombox Project - The Madeleine

Subscribed.

[greywarden]

Re: 1st Boombox Project - The Madeleine

That's a solid start!

[joeybutts]

Re: 1st Boombox Project - The Madeleine

Sick. Did you make those boards? I like that..... Looking good.

[Dewmiester]

Re: 1st Boombox Project - The Madeleine

Looks like a good project.

The second pic reminds me of my old Pioneer receiver.

[Eternal Student]

Re: 1st Boombox Project - The Madeleine

I've been digging around the Googles and I haven't been able to find that crossover PCB. Where did you get it from and how can we order some? It makes the build so very clean looking.

[Gordy]

Re: 1st Boombox Project - The Madeleine

I've been digging around the Googles and I haven't been able to find that crossover PCB. Where did you get it from and how can we order some? It makes the build so very clean looking.

I found the PCB boards on that auction site that folks love to hate. If you zoom in on the pic you can see the brand name. They have boards made specifically for the OS’s in the MT and MTM configurations. I was very surprised when I found them as I have never seen anyone use them before. They are 2mm boards and super tough. They are also very worthy of displaying if you could. They really are gorgeous and are 5”x3” exactly which allows placement just about anywhere in a speaker enclosure. The speaker wire terminals will accommodate 16GA wire as well. I am using 16GA for everything in this build.

These boards use all of the same parts except for the 6.8 cap. The 6.8 cap in the parts list is too large for the footprint of the board and it requires a physically smaller cap. So instead of 027-424 use 027-336. This was listed in the PCB detail but I had already ordered the parts. I have (2) of the 027-336 caps inbound tomorrow.

In the pic below is the finished crossover sans the 6.8 cap. It really makes the crossover assembly super easy. If you notice the holes in the board underneath where the components go, that is for glue to have something to grab onto and secure the components. I will be building more of the OS speakers and these will be prerequisite for each build. At $30 for the pair, no brainer.

I will also try to upload a few more pics this evening.

[Gordy]

Re: 1st Boombox Project - The Madeleine

Testing the recessed driver cuts. I do not have a plunge router but do have a regular router and a drill press. The final cuts in the oak baffle were near perfect. No need for a router or circle cutting jig. If I did this more, both would have a place in my tool box. I used a circle cutting bit in the drill press and a 1/2" rabbit bit on my router for the woofer. The pace needed to sink the woofer was about .489". So, the 1/2" bit worked very well. The requisite 45mm forester bit was used to recess the tweeter. I have an old 1 1/4" hole saw that wobbles just a little bit. It makes a perfect snug fit hole for the tweeter. Like tough to press in snug. I call this a win.

[Gordy]

Re: 1st Boombox Project - The Madeleine

Drilling the holes to mount the amp and crossovers and other stuff. I countersunk these on the bottom of the box so they would be hidden. I am using #8 1-1/4" 10-32 machine screws, 1/2" nylon spacers and a rubber washer for vibration. This way the crossovers would not be permanently mounted. If I wanted to remove them for another project I could.

The amp utilizes the same set up but with #6 machine screws same length and spacer. I did have to drill out the amp and the crossovers to accommodate the machine screws. Just a little bit larger than the original hole and the drill press took care of the task easily.




The 4 holes countersunk on the corners are for the Penn-Elcom rubber cabinet feet (F1633). They are 1-1/8" wide and 1/2" deep. I wanted the cabinet close to the surface it was on and to look like is blended into that surface. So I countersunk them with a 1-1/8" forester bit 1/4" deep. The result was really cool. They fit snugly in the cut out and raise the box up off the surface just enough.




The electrical components for power are a switch for on-off power, fuse holder (070-610) to protect the electronics and a plug for the AC Adapter (090-496). These are mounted in the back of the box and recessed as much as possible to give the back a smooth look fro the side. Side Note: the next box will have a USB charging port were the fuse holder is. The fuse holder will be moved to the bottom of the cabinet.

Fuse Holder

[Gordy]

Re: 1st Boombox Project - The Madeleine

Assembly of the cabinet. Test fitting the dowel holes and the inside structure of the cabinet.






I cut some pine spacers that allowed me to glue the structure up square.

[Gordy]

Re: 1st Boombox Project - The Madeleine

Cutting out for the speakers in the baffle. It took 5 tries on scrap wood before I got the circle just right and the driver snug.



Here is that wobbly holes saw after counter sinking the tweeter.







Test fit of the tweeters before the the woofers were routed out.

[greywarden]

Re: 1st Boombox Project - The Madeleine

It's looking good!

[Gordy]

Re: 1st Boombox Project - The Madeleine

It's looking good!

Thanks! I sprayed the last coat of finish this evening. I should have it up and running in the next few days. I will try to post more pics in the next day or two

[Gordy]

Re: 1st Boombox Project - The Madeleine

Gluing in the ports. I chose not to use the standard ports for the OS's. The flange on the back was too big for the back panel and they would not have blended in with the all smooth look. I countersunk the ports 3/8" into the back panel. It adds 3/8" so I cut the PVC to 5-5/8". I used Gorilla glue because of it expanding properties. There is a 3/4" hole in the port that is just big enough to get a flush cut router bit in. I saw this on another project and thought it was really neat so I decided to use that technique on this project.