How to Make a Plexiglass Subwoofer Box
- 1). Consult the subwoofer manufacturer's recommendations for speaker enclosure size. Cut the sheet(s) of Plexiglas to create the correct-sized panels, using the wet saw. Leave the backing on the Plexi while making the cuts. Set the faceplate or baffle board aside.
- 2). Drill a 1/8-inch hole every 3 inches along the outer facing edge of each panel.
- 3). Drive a 1-inch stainless steel wood screw into each hole on the enclosure (except the baffle board), forming the box.
- 4). Screw a single screw through the hole on the circle jig that corresponds with the circumference of the driver that will be installed in the Plexi box. Slide the other end over the guide post on the router.
- 5). Route out the driver circle, letting the jig guide the tool.
- 6). Screw the baffle board to the rest of the enclosure, using the drill, Philips bit, and stainless steel screws.
- 7). Drill a 1-inch hole into the side or back of the enclosure for speaker wire.
- 8). Seal the inner-meeting edges of each panel on the enclosure with the clear silicone caulk.
- 9). Remove the paper backing from the Plexiglas sheets after all cuts are made and holes are drilled.
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