Bronco Subwoofer Box Build - Double Baffle, 45's, Custom Insert Work

[caraudiofab]

Recently built this subwoofer enclosure for 2 12's in a Bronco. I wanted to share the build pics with you all.

Started with some wood cut down from the local store:



Made all my cuts using a table saw





Did some work on the front baffles:



Used a Fukuda router tool to make a perfectly rectangular port:

[caraudiofab]

Next I used one of my mini bits from my Mobile Solutions set to add a small roundover:







I also added a roundover to my port.



Baffle looks much better:



Here is a sick trick, go extra deep on your roundover on the port entrance, it will leave a hard edge to cut carpet on later.

[caraudiofab]

Painted all the inside pieces black:



Used this sick huge rabbeting bit I got from Mobile Solutions to cut this notch in the corner of the side pieces, this is also for carpet wrapping:



Started the assembly process using clamps and wood glue:





Box is really taking shape now:









Now we need to add a bit of custom flair. Lets add this shape here for highlighting an embossed logo. Im using a smart template.

[caraudiofab]

Copied the shape to 1/2 MDF and protected it with TESA tape:



Applied body filler using a smart spreader:





Sanded and looking smooth



Look how perfect that transition is:

[caraudiofab]

Now we need to make our insert fit after vinyl and carpet is applied. This means we need to remove material from the wood of the piece otherwise it wont press fit. I use the material compensation set from Mobile Solutions:










Now it fits perfectly:





Wrapped the insert with vinyl:

[caraudiofab]

Now I am going to add a logo. Im using speedfoam from Ultimate Audio Fabrication for an embossed look.

[caraudiofab]

Now the box is complete!













Packed up for loading into a cardboard box.

[caraudiofab]

Finally, here is a video showing the whole process

[Optimaprime]

Badass man hope it ships ok

[JayinMI]

Here is a sick trick, go extra deep on your roundover on the port entrance, it will leave a hard edge to cut carpet on later.

I like to make the outer layer about 1/8" or so bigger than the actual port so I can wrap the carpet INTO the port. I then either staple or glue the carpet in. This way you don't see the cut edge of the carpet.

Jay