How do I build my own subwoofer enclosure?

Materials and tools you will need to do this:

• Wood - MDF or Supawood would be the best, 3/4" thickness, to ensure the enclosure stays rigid.
• Adhesive - Cold wood glue is the most commonly used.
• Screws - 1 3/4" to 2" wood or drywall screws will work.
• Silicone Sealant - This is needed to make sure the inside of you enclosure is as airtight as possible, rub this in all the corners.
• Terminals - Do you really want to connect naked wires to your amps? This will reduce possibility of shorting and makes much cleaner wiring. If you can get hold of a terminal cup, it will makes things look more professional.
• Table/Radial saw - For cutting wood to size, if you haven't asked the timber store to cut it for you.
• Jigsaw - For cutting holes like ports and speakers.
• Pencil & Measuring tape - To measure and make marks, also good for writing down measurements and notes.
• Drill - Just to create counter sink holes and if you don't have the leverage power in your arms tighten screws with a screw bit, makes life a lot less difficult when screwing things together.

After you have worked out all the dimensions, volume and other calculations, start by tracing out the panels of your enclosure on the wood. Using the table or radial saw, cut out these panels. You should end up with at least six panels, more if you also cut any bracing panels.

Take the front panel and make trace lines for the subwoofer hole(s) using the template on the subwoofer's box, or if you don't have it, take a measurement of how wide the lips of the sub is to the basket, double that and then subtract from the sub's total diameter. Now use the jigsaw to cut the hole(s), but first drill a hole big enough for the blade on the inside of the cut-out to make it easier to saw.

Now if you do have a terminal cup and trace the hole for it on the back board of the enclosure. Now cut it out or cut holes for the type of terminals you are going to use.

Assemble the enclosure by starting with an end panel and a bottom side panel. First line the pieces up and drill sink holes about 8" apart. Apply a small bead of adhesive on the edge of the end panel that will be facing the side panel. Fit it together and turn it so you can screw them together, and spread the excess glue along the seems. Now affix all the panels in the same way. Now seal the enclosure by rubbing silicone in all the corners and seems and around all holes. Let the enclosure dry overnight.

You may want to cover the enclosure before finishing up. Now fit the ports, cables and fit the sub(s) in the hole(s). Apply a small amount of silicone around the speaker and port surround to make sure you have a sealed unit. And there you go... the enclosure is now done.