Blue­tooth Box-Joint Speaker

The Family Handyman - - CONTENTS - BY MIKE BERNER

Build this beau­ti­ful hard­wood heir­loom in just one day—and learn a new tech­nique too.

Sure, a store-bought speaker can sound good, but how at­trac­tive is a plas­tic box? Here's a hand-built heir­loom speaker that re­ally turns up the vol­ume on looks. Mak­ing a speaker your­self al­lows you to mix and match hard­woods. This one, made of elm and maple, is con­structed with box joints, mak­ing it as fun to build as it is to give.

1. SET UP THE DADO BLADE

Set the dado blade height a hair taller than the thick­ness of your ma­te­rial. The dado width should be 1/2 in. to match the width of the key stock.

2. PO­SI­TION THE KEY

Use the left­over 1/2-in. x 1/2-in. stock to po­si­tion the key away from the blade. The widths of the blade, the spacer and the key must be equal. Clamp the plate to the fence.

3. CUT THE FIRST PIN

Set the top/bot­tom parts (A) against the key. Make a ref­er­ence mark on the front and back of the pin that will set up cuts for the sides.

4. CUT MORE PINS

Fit each socket over the key to per­fectly po­si­tion the next cut.

5. CUT THE SIDE PINS

Set the top/bot­tom (A) on the key so the ref­er­ence mark is be­tween the key and the blade. Then make the first cut in the side (B).

6. GLUE CLEATS TO AT­TACH THE PAN­ELS

Scribe a line 5/8 in. in from the edges of the pan­els and glue the eight cleats along the in­side of these lines.

7. GLUE AND CLAMP

Ap­ply glue to all sur­faces in the sock­ets, fit the parts to­gether and clamp tight.

8. BORE HOLES FOR THE COM­PO­NENTS

For larger holes, you’ll need to use a hole saw at the drill press. Drill part­way through one side, then fin­ish the hole from the other side to avoid ma­jor chip­ping.

9. CHAMFER THE SPEAKER HOLES

Make shal­low passes with a 45-de­gree chamfer bit. Be aware of the thick­ness of the sur­face where screws will at­tach the speaker, to avoid screws pok­ing through.

10. CON­NECT THE SPEAKER COM­PO­NENTS

In­stall the com­po­nents onto the front and back pan­els and sol­der nec­es­sary wires to their ter­mi­nals.

11. IN­STALL THE FRONT AND BACK PAN­ELS

Glue the front panel onto the front cleats and drill pi­lot holes into the back panel to screw it to the back cleats.

Spacer Fence Key Plate

Side Top/bot­tom Ref­er­ence mark

Top/bot­tom Pin Key

Socket Ref­er­ence mark

Cleat Cleat

Front panel

Chamfer bit Chamfer

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