The wood
When building a speaker box, it is important to use a good-quality wood. MDF, which stands for medium-density fiberboard, is recommended, but a high-quality particle board can also be used. The idea is rigidity, which both types of wood will provide. Thicker is almost always better, but for 8- or 10-inch subwoofers you can get away with using half-inch MDF, and three-quarter-inch for 12-inch subs or bigger. It is always better to use wood that is too thick than too thin so that the sound is trapped inside and can only escape through the speaker itself. A 4-by-8-foot sheet of MDF usually costs around $20. The size requirements of the actual enclosure varies greatly from speaker to speaker due to power output and cone size, so contact the manufacturer to see what the optimal size should be for your particular speakers.
Building the Box
When you decide on the dimensions of the box, there are a few things to keep in mind that will greatly help its quality. First, it is very important that all the seams meet up as neatly as possible to keep the edges of the box straight. Apply silicone caulking wherever wood meets wood before you screw it together, so ensure an air-tight application. Recommended are 1 ½-inch drywall screws. You can also use silicone between the speaker and the box, if it is going to be a permanent home for the sub. The hole in the box can be cut out easily by measuring the INNER diameter of the mounting flange and marking it with a pencil, then using a jigsaw to trace the circle. Or the outer edge of the speaker can be traced onto the wood, and then the cut can be made a half-inch inside that circle to ensure a solid mounting surface. Speaker box carpet can be purchased at most stereo stores, and is best applied with a staple gun, and in as few pieces as possible. The idea when carpeting is to protect the screws and the wood from contaminants while at the same time making the box nicer to look at.
Accessories
Before the speaker is permanently installed into the box, remember to route speaker wire from the back of the terminals on the sub to the speaker fittings in the back of the box. This means you'll need speaker wire, and for any sub it is recommended to use 10-gauge or bigger (numerically smaller). You may also want to consider the installation of a speaker grille to help protect the sub, especially if it is an auto application. If the box ends up being really heavy, handles can also be installed either on the top or sides for ease of movement.
Tags: always better, speaker wire
