Hacks and Mods: Making High Quality iPod – iPhone Speakers

This high quality and
low cost speaker was designed to be used for iPod or iPhone with the use
of old car Hi-Fi speaker and some computer components. Other materials
used are shown in the image below and they include an amplifier,
240V-12V power supply, tweeters, crossovers, sealed lead acid battery, MDF, filler, Apple universal dock & remote, glue, nails, and white gloss paint.

The front baffle board was drawn on a piece of MDF
in order to use it as a template to make the rear of the box. The
dimensions of the box based on the speaker do not necessarily need to be
exact because the speakers were quite old as it comes from an old
Renault 19.

From the photo of the round bits below, the trusty circular saw was used to cut loads of 1 inch by 15 cm strips of MDF.
Between the front and rear baffle, the strips were glued and nailed.
The baffles were cut out using a jigsaw and the strips were kept as
close to each other as possible.

The first coat of filler can take 3 batches to finish and they were
applied as neatly as it can after being mixed up. Until it was somewhere
near as shown below, a few more coats can be applied. A surform will be
applied until it was about the right shape once the first coat of
filler had set. Sanding could be done by hand or it would be better to
use an electric sander if available. A jigsaw was used to cut out the
speaker and tweeter holes as shown below and a flange for the speaker to
sit into was made using the router.

A hole of about 12mm on the top and 3mm on the back were drilled
once all the holes were cut. The edges were masked up and the baffle was
spray painted in matt black as shown below. The first layer of white
primer can be applied once the black was dry and the masking tape was
removed. A couple of coats of normal white primer was applied and then
followed by a light sand. In between, a bit of sanding was applied as 3
coats of white gloss were given.

A grill for the front had to be made for the full fake Apple. To
mark out the shape on a scrap bit of 5mm laminate flooring, this was a
simple matter of using the box as a template and then sprayed it in matt
black. Some black nylon cloth was glued onto the panel with some spray
carpet adhesive when the paint was dry as shown in the image below.

Some black drywall screws were used to screw the 13cm speaker into
the box as well as the amp and crossover networks and epoxy resin was
used to glue the tweeters. After soldering all the connections, the lead
acid battery was glued inside as shown in the next image. The amp of
the battery was powered by wiring the 12V to the battery. The iPod
universal dock was glued on the top of the box with wires for USB and audio. The finished product of cool looking iPod speaker is also shown below.

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