I have been noticing that many of the Pakwheelers dont know anything about box making. well lucky for you guys i was in process of making a box for my woofer, which by the way is not a conventional type box as you will see at the end of the tutorial. so i thought that why not help you guys out with the whole thingy. so here goes nothing...
So the first thing you do is measure the available space in your trunk. you have to know all the important dimensions like height, and width and depth at various places.
The pictures and measurements are for reference only and taken from South Bay Sedan & Limo Service - Private Airport Limo Sedan Servicing the Greater Bay Area. my car is a baleno without cng so i had loads of space in it.
this is the trunk of my car the max height is 13.5" inside width where i want to fit the box is 34".
since most rear seats are somewhat slanted, i wanted to have a side of the box slanted to take up that space but it was becoming too complicated to calculate so i went on with a straight back.
Then i went to the woofer manufacturer's site and got the recommended box volume from them. in my woofer's case, it was i.75 cu. ft.
so next step is to start a good box design program like bass box pro. i noticed that one of the shapes i.e. prism, trunc.edge when multiplied by two gives me the shape of the inside of my car trun. so i put in volume as "Half" of what i want, i.e. 0.875 cu ft. put in the measurements i had and ran to my car to take another measurement i.e. F=6". this gave me the other dimensions i need to make a box of 1.75 cu. ft.
next i went to the wood market (City saddar road in Rawalpindi) i figured that a half sheet (4X4 feet) of 0.75" LAsani wood AKA MDF will be sufficient for the box. so i bought the sheet.
this is what it looks like from the edge.
then i took the wood to a wood worker/carpenter/tarkhaan and showed him the shape i wanted. now you can take it to the audio walas but those guys charge u an arm and leg, are LAZY and wont work the way you want to do. the guy i went to is an expert. his shop is under the westridge masjid. didnt charge me much either. make sure you ask your guy to use screws only. its a good idea to pre-drill the holes in MDF as the wood has a tendency to split. he used long wood screws and lots of wood glue to make the box strong.
Its a good idea to check if the box fits in the trunk or not.
next step is to seal the box with silicon glue. you can also use sawdust mixed with wood glue. make sure the box is well sealed from the inside.
Also since i am gonna be using a special type of baffle board, i used some leftover underlay from my sound deadening project and used it on the edges that the baffle board will be mounted on. for those who dont know what baffle board is, its the board on which u mount the woofer.
well my baffle board happens to be sthg different. kher. you can mount your baffle board without the underlay. dont forget to sel it as well beofre you put in the subwoofer. my baffle board took me hald an hour to cut. then i put some foam on the back of the woofer ring so that air does not escape from between the woofer and baffle board. used couple of nuts (you can use screws and T nuts) and mounted my woofer in.
you would notice that baffle is not attached to the box, the holes for wire and port are not cut. well i have bass box pro to help me with the dia and length of the port.
i will be cutting that tomorrow and wiring it, maybe a coat of paint and cover. thats for tomorrow though
