Here are the designs and drawings of my cool dice speakers I made.
It is quite a hard, complicated and long process but it is worth it.
Materials and equipment:
-MDF wood 6 mm thick.
-ply wood between 12 mm thick and 20mm.
- A Speaker kit (here is a link) which can either run on battery or mains current.
-1 x TDA2822M audio amplifer IC
-1 x 8 pin IC holder
-1 x 1Kohm resistor
-2 x 10Kohm resistors
-1 x 10Kohm dual potentiometer
-2 x 4.7ohm resistors
-1 x Red 5mm LED
-2 x 100nF capacitors, ceramic disc
-2 x 470uF capacitors, electrolytic
-2 x 100uF capacitors, electrolytic
-1 x 10uF capacitor, electrolytic
-1 x iPod cable
-1 x PP3 clip lead
-1 x right angle power switch
-1 x DC power socket
-2 x speakers (8ohm, 66mm) and connecting wire
-1 x deluxe stereo amplifier PCB
-Spray paint (primer and final coating) Which ever colour you want.
-Sander / Sand paper
- PVA glue and Alraldite glue.
-Drill and drill bits.
Don't forget to check out my other projects :)
Take a look at my new project i have uploaded http://www.instructables.com/id/Coca-Cola-bottle-light/
Step 1: Making the box
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Cut four pieces of MDF wood 100 mm by 100 mm, another four 100mm by 88 mm and another four 88 mm by 88 mm. This once put together should give you 2 boxes 100 mm by 100mm. Make sure you are precise so that all the pieces can fit together nicely. (If you are using a different thickness of MDF wood then calculate how big your pieces must be so that it is a 100mm by 100mm box).
Then cut the hole for the speaker to sit in, in 2 of your 100 mm by 100 mm pieces of MDF. using a circle cutter make sure you use a circle cutter with a diameter a little bit smaller than the speakers diameter.
Step 2: Dice holes
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Then you needed to drill the holes for the dice, so measure up where they should all be and marked the centre of each one with a little hole so that the drill can be accurately set up.
I used a size 19 drill piece for this, but you can choose which ever size you want. Do a few test runs on a scrap piece of wood so that you can set the deepness the drill goes in, do not make it go in to far. Make sure you are drilling the right amount of holes on each side so that it resembles a dice.
Step 3: Cutting/drilling all the holes for the electrics
After cutting the dice holes, cut the holes that the wires are going to go through once the speakers have been assembled, you need 2 holes for the wires on the main speaker and 1 on the other speaker ( these should be drilled into the side six of the dice speaker, the back piece). Also drill the holes for the volume adjuster to come through. And also carve the hole for the on off switch to come through using a chisel (these should be in the bottom 2 dice holes of your sixth side of your main speaker), if you use the kit I recommended then the on off switch should hold on its own in the slot, if not you can use a lollypop stick to hold it in place as shown in the pic.
Step 4: Gluing some parts together
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Now you have to cut the ply wood into long square sections these will act as your inner joints to hold everything together.
Cut them so that they can fit all around an 88mm by 88mm piece of MDF. Repeat this for the four 88 mm by 88 mm piece of MDF you cut out. Then glue the inner joints onto the 88mm by 88mm pieces of MDF using PVA glue make sure they are as close to the edge as possible, for this you can use scrap pieces of wood which you put around the sides but put some bee's wax on them so that they don't stick to the 2 woods you are gluing. Use G clamps to hold down the strips of ply wood and wait for the glue to set. It should look like picture 6 when done.
Once you have done that glue the front piece ( the one with the hole for the speaker in it) and the back piece onto only the speaker box that won't have the circuit board in it. Now sand down all the edges to make a perfect box.
Step 5: Painting
Now you need to paint the 1 speaker you have completed, using spray paint. First use a primer coating have a few layers of these and at this point if you see any holes in your speaker for example at the joint, fill them in with PVA glued mixed with saw dust. Then once you have got a few coats of primer paint, spray paint it with a few layers of whatever colour you choose I used green. Remember NOT to put to much paint on at one time other wise it will wrinkle.
Step 6: Painting the dots
then take a piece of thin plastic and cut a 19 mm hole in it so that you can paint the black dots on your dice without getting paint everywhere. Place the hole over your drilled dot and then spray paint with whatever coulor you choose I chose black.
Step 7: Making the battery cover
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If you are going to use the battery pack, (you do not have to), then you will need to cut a hole in the bottom piece of speaker 2, it must be big enough to fit the battery pack + space for the magnets on each end to holed the piece which will conceal the battery pack as you will see in my picture I had not thought about that so I had to cut it longer(the hole).
So now cut out a piece of MDF that is the same size as your hole and then place it into the bottom piece and line up the 19mm drill piece to cut out the dice dots again so that your battery pack lid (the MDF piece of wood you have just cut out).
Then glue the magnets, that will hold the cover on.
Step 8: More gluing
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Now glue all the parts together, like before making sure all the electronics are in the right place as you can't change them after that.
Once you have glued it all together you may need to cover the electronic part and do a bit mor painting to make it look really nice and smooth.
Step 9: The finished product
And there you go, this project is quite easy just the painting is rather difficult as you have to paint when all the electronic components are in place.
I hope you like it and please ask any questions.
I would love to see your ones if you make any, so keep me posted.
and don't forget to vote for me!!!!!