Wesley Miaw

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Sealed Sonotube Subwoofers
Photos of the two sealed sonotube subwoofers I built. My quest for perfect low frequency reproduction, within the limits of cost and construction. Two sealed 20" diameter subwoofers with four total 15" drivers. They will be paired with a Behringer EP2500 and DCX2496.
Date: 2007.07.29
Size: 34 items
Views: 30365
3/4" MDF
Item Actions3/4" MDF
The end caps will be constructed from 3/4" MDF layers.
Date: 2006.11.12
Views: 2908
The end caps will be constructed from 3/4" MDF layers. I purchased the MDF from Home Depot and the employee there was nice enough to cut the 4'x8' sheet into approximately 2'x2' squares. 2006.11.12
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Routing an End Cap
Item ActionsRouting an End Cap
Using a plunge router and jig to cut the end cap.
Date: 2006.11.12
Views: 3351
Using a plunge router and jig to cut the end cap. The outside edge of the end cap is exactly the diameter of the outside of the sonotube so it will sit flush. I should have purchased a larger jasper jig for more precise cuts. 2006.11.12
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Naked Sonotubes
Item ActionsNaked Sonotubes
The sonotube forms that will act as the subwoofer enclosures.
Date: 2006.11.12
Views: 2559
The sonotube forms that will act as the subwoofer enclosures. The tubes are four feet tall and 20" in diameter. The walls are 1/4" thick. I purchased them from a local concrete supply company. The surface looks smooth here, but it actually has bumps at the external seams. The internal seams are smooth. 2006.11.12
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Routing End Caps Outside
Item ActionsRouting End Caps Outside
The routing setup in my driveway.
Date: 2006.11.12
Views: 3241
The routing setup in my driveway. I switched to using the router outside in the driveway because of all the dust being produced. It's very important to wear a high-quality respirator while routing MDF. 2006.11.12
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Clamping End Caps
Item ActionsClamping End Caps
Two layers of 3/4" MDF glued together and clamped.
Date: 2006.11.14
Views: 2943
Two layers of 3/4" MDF glued together and clamped. I purchased bar clamps to ensure the end caps would glue together without any gaps. 2006.11.14
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Wood Glue Between Layers
Item ActionsWood Glue Between Layers
MDF layers are glued together using wood glue.
Date: 2006.11.14
Views: 2934
MDF layers are glued together using wood glue. The little nail in the center was to drop the layers on top of each other. In retrospect, it was better to just line them up visually and by touch. That resulted in a better alignment. 2006.11.14
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Two Layers of MDF
Item ActionsTwo Layers of MDF
This part of the end cap consists of two MDF layers.
Date: 2006.11.14
Views: 2129
This part of the end cap consists of two MDF layers. Each layer is 3/4" thick and they are aligned using the pivot hole used for the router. 2006.11.14
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Clamped Inner Endcaps
Item ActionsClamped Inner Endcaps
The four end caps' inner layers of MDF.
Date: 2006.11.14
Views: 3186
The four end caps' inner layers of MDF. The layers were clamped together overnight to ensure the wood glue bonded well. I used Tightbond II wood glue and then sanded off any that was squished out the next day. 2006.11.14
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The Inner Cut
Item ActionsThe Inner Cut
Cutting out the inner circle of the end cap.
Date: 2006.11.18
Views: 4375
Cutting out the inner circle of the end cap. The driver will sit in this hole, and be screwed into the MDF. 2006.11.18
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Cutting the Outer Layer
Item ActionsCutting the Outer Layer
The third layer of MDF for each end cap.
Date: 2006.11.18
Views: 1889
The third layer of MDF for each end cap. This layer has an outer diameter equal to the outer diameter of the sonotube. The inner hole diameter will allow the driver to fall through, where it will sit on the inner layers. 2006.11.18
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Clamped Inner and Outer Layers
Item ActionsClamped Inner and Outer Layers
The outer layer of MDF is glued to the inner layers.
Date: 2006.11.19
Views: 4486
The outer layer of MDF is glued to the inner layers. The outer layer is slightly larger in diameter as it must not fall inside the sonotube. The two inner layers will go inside the tube and serve brace for both the tube and the driver. 2006.11.19
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Prepping Driver Holes
Item ActionsPrepping Driver Holes
The driver's screw pilot holes need to be drilled.
Date: 2006.11.19
Views: 2796
The driver's screw pilot holes need to be drilled. To identify the drill locations, I placed the driver into the end cap and tapped the screws down to dent the MDF. The dented locations will be where I drill the pilot holes. 2006.11.19
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Three-layer End Cap
Item ActionsThree-layer End Cap
The end cap with all three layers of MDF glued together.
Date: 2006.11.19
Views: 3805
The end cap with all three layers of MDF glued together. The outer layer is 20.5" in diameter with a 16" cut out as the drivers are 15.65" in diameter. The inner layer is 20" in diameter with a 14.125" cut out. 2006.11.19
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End Caps Primed
Item ActionsEnd Caps Primed
The four end caps covered in white primer.
Date: 2006.11.20
Views: 3355
The four end caps covered in white primer. It's important to use primer so the black paint will stick correctly. 2006.11.20
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Base Plates Painted
Item ActionsBase Plates Painted
The base plates and legs painted black.
Date: 2006.11.20
Views: 2876
The base plates and legs painted black. The base plates are the same size as the end cap outer layer. The 2" tall legs will be placed between the base plate and the bottom end cap to hold the subwoofer up. 2006.11.20
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Sanding the Paint
Item ActionsSanding the Paint
Initial layer of paint was sanded down.
Date: 2006.11.22
Views: 3018
Initial layer of paint was sanded down. Sanding down the paint and then applying another layer helps create a smooth end product. Without sanding down, the finish is bumpy to the touch. 2006.11.22
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Polyfill Stuffing
Item ActionsPolyfill Stuffing
The inside walls are covered in polyfill stuffing.
Date: 2006.11.22
Views: 3176
The inside walls are covered in polyfill stuffing. Many people argue this isn't necessary, or at least not to the amount I put in. However, it doesn't hurt that much, and some of it will fall out as construction continues. I ordered 10 pounds from Robey's Fabrics, but ended up using only about 2.5 pounds. 2006.11.22
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Applying the Veneer
Item ActionsApplying the Veneer
Cherry veneer from Parts Express.
Date: 2006.11.23
Views: 3234
Cherry veneer from Parts Express. Unfortunately I don't have the best veneer applying setup, but it wasn't too hard. You can see the sonotube seams through the veneer. If you use fabric they won't be visible, and some people try sanding them down or covering the tube with drywall mud. 2006.11.23
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Rolled Veneer
Item ActionsRolled Veneer
The sonotube completely covered in veneer.
Date: 2006.11.23
Views: 2842
The sonotube completely covered in veneer. After completely covering the tube in veneer, I used a utility knife to trim the edges. 2006.11.23
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Internal Wiring
Item ActionsInternal Wiring
These wires will be used to connect the binding posts to the drivers.
Date: 2006.11.23
Views: 3235
These wires will be used to connect the binding posts to the drivers. I am using 14/4 (four runs of 14awg) in-wall cable from Impact Acoustics. I won a spool of the cable for entering a haiku contest a while back. The four runs are paired up so each signal path will be 11awg. The total cut length is 3'. 2006.11.23
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Internal Wiring End
Item ActionsInternal Wiring End
A photo of the paired runs for the internal wiring.
Date: 2006.11.23
Views: 3107
A photo of the paired runs for the internal wiring. Niea was watching closely. 2006.11.23
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Veneer Complete
Item ActionsVeneer Complete
Both sonotubes covered in cherry vinyl veneer.
Date: 2006.11.24
Views: 2432
Both sonotubes covered in cherry vinyl veneer. The excess was removed with a utility knife. Doesn't look too bad from a distance, although the seams are still visible. 2006.11.24
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Brass Bolt Binding Posts
Item ActionsBrass Bolt Binding Posts
The inside half of the binding posts are brass bolts.
Date: 2006.11.25
Views: 1706
The inside half of the binding posts are brass bolts. No one makes binding posts that are long enough to go through three layers of MDF. Most people don't have three layers, but I don't see why no one makes them. However, brass bolts are easily found up to 4" in length at Home Depot. This is a 1/4" x 2" bolt inserted on the inside. Its flat end will push up against the flat end of the binding post coming from the outside. Thus completing the circuit. The multimeter is there to ensure the circuit is good, as any bits of wood or a non-flush contact will render the subwoofer useless. 2006.11.25
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Brass Bolts Completed
Item ActionsBrass Bolts Completed
The brass bolts have been fully inserted.
Date: 2006.11.25
Views: 1829
The brass bolts have been fully inserted. Both positive and negative leads are attached, with a washer holding the soldered lead against the bolt head. The machine screws are driven all the way in to prevent the leads from moving around and possibly creating a short. 2006.11.25
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Binding Posts
Item ActionsBinding Posts
The short binding posts as seen from the outside.
Date: 2006.11.25
Views: 2786
The short binding posts as seen from the outside. These were ordered from Parts Express and screwed directly into the outside of the end cap. The flat end of the binding post will hit flush against the flat end of the brass machine screen to complete the circuit. 2006.11.25
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Final Enclosure
Item ActionsFinal Enclosure
The completed enclosures.
Date: 2006.11.26
Views: 2467
The completed enclosures. Both end caps and the base plate have been attached to each subwoofer. It was extremely difficult to get the last end cap in, which ended up creating quite a bit of cosmetic imperfection on one of the enclosures. Alla helped (thanks!) and we both ended up with glue on our hands. 2006.11.26
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Stuffing and Glue
Item ActionsStuffing and Glue
Inside the completed enclosure.
Date: 2006.11.26
Views: 1510
Inside the completed enclosure. You can see the wood glue that dripped down while drying. A lot of glue was used to ensure a tight seal, and then all seams were heavily caulked to prevent air from leaking. 2006.11.26
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Bottom Driver Installed
Item ActionsBottom Driver Installed
The bottom driver installed and legs ready for base plate.
Date: 2006.11.26
Views: 2382
The bottom driver installed and legs ready for base plate. This configuration was the only way I was able to attach a driver and screw it in. Way too heavy to try and attach a driver horizontally. The only way to get the driver out is in this position using a flat head screwdriver and soft protection on the enclosure to pry it out. 2006.11.26
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Base Plate Attached
Item ActionsBase Plate Attached
The base plate attached to the subwoofer.
Date: 2006.11.26
Views: 2365
The base plate attached to the subwoofer. The base plate is screwed to the end cap through machine screws that go straight through the legs. The screw heads are flush with the base plate and little rubber feet cover them. 2006.11.26
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Completed Subwoofers
Item ActionsCompleted Subwoofers
The subwoofers completed assembled.
Date: 2006.11.27
Views: 1687
The subwoofers completed assembled. One has a 15" Parts Express metal grille placed on it to protect the driver, as otherwise it would be completely exposed. The other will have a grille attached as well. Unfortuantely, the grille does not fit normally. But I was able to use the speed clips in a non-conventional manner to hold the grille in place over the driver, without the grille's inner ring. I got lucky that the speed clips can be wedged in the space between the driver's rubber frame endcap's top layer. 2006.11.27
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Top Driver Grille
Item ActionsTop Driver Grille
A close-up of the grille placed over the top driver.
Date: 2006.11.27
Views: 2818
A close-up of the grille placed over the top driver. The grille is held in place with the wedged speed clips, and without its inner frame. This will protect the driver in case anything falls down onto the subwoofer. 2006.11.27
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4" Base and Top Plates
Item Actions4" Base and Top Plates
A full-length shot of the subwoofer with new 4" legs and a top plate.
Date: 2007.12.19
Views: 17847
A full-length shot of the subwoofer with new 4" legs and a top plate. The grille previously used on top has been replaced by a top plate to provide protection without interfering with driver excursion. The grille did not allow enough displacement for very low frequencies. 2007.12.19
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New Top Plate
Item ActionsNew Top Plate
A close-up of the top plate on 4" legs.
Date: 2007.12.19
Views: 27720
A close-up of the top plate on 4" legs. The top plate provides protection for the driver while the four inches of clearance provides a cylindrical surface area greater than the surface area of the driver. 2007.12.19
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4" Legs for Base Plate
Item Actions4" Legs for Base Plate
A close-up of the base plate with new 4" legs.
Date: 2007.12.19
Views: 21180
A close-up of the base plate with new 4" legs. The base plate has had its leg length increased from 2" to 4" to provide additional clearance for air displacement without exerting pressure back on the driver. 2007.12.19
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