Custom Subwoofer Build (Lots-o-pics)

[lcdrbrentcarroll]

OK... so my brother went out two weekends ago and bought a subwoofer and amp for his car. Now, before this I was completely satisfied with my JBL system and I am NOT an audio expert by any stretch, but when I heard his system with just that mod, I just had to have one. The base was so AWESOME!! Now, don't get me wrong... I just turned 40, so I wasn't looking for some window rattler, just something to enhance what I thought was a good system. So, I went online shopping and found this...

http://i207.photobucket.com/albums/b...13694340-f.jpg

It is a custom fit for the Tundra DC, but I was SHOCKED to learn it was like $600!!! It included a speaker, but not an amp.

I am like... WOW!! This can't be that hard to make. I have tools, a not-so-perfect-ruler, and some time, so I said what the hell... Here's the stock I pulled out.... Easy to pull out... it had fout bolts.... it's a sealed unit with one very cheap speaker in it.

http://i207.photobucket.com/albums/b...0001_small.jpg


So next I made a prototype using that $600 model above. I used 1/2 plywood. I stole the stock speaker and connector, put it all together, slid it under the seat, and plugged it in.... here it is, what I'll call the prototype...

http://i207.photobucket.com/albums/b...0003_small.jpg

You can see the stock connector on the left.... and that's the stock speaker.

The box is shaped funny, I know. But I downloaded the owner's manual from that $600 mojo above and saw there's room behind the seat but you'll have to remove the seat bolts and seat belts to raise the seat to slide this under. But, once there all is well.

Now, no, it does not have a sound port, only a hole that I drilled, but holy crap, with just that one change the increase in sound was dramatic... that bass just BOOMED. By the way to make that box cost me exactly $20. But, I wanted to use all the space under the seat, so I went back to the drawing board.

I'll go on now to show you how I made the final product.

So, first, I ordered a new speaker (the stock one is made of paper), and an amp. I didn't spend much money on them, some of you may eve say they are crap... but to me, better than paper (speaker), and nothing (amp). I also ordered a sound port (2") for $3 and a connector plate (8.99). All of this I got at Crutchfield.

Here's the speaker - It's a Phockford Rosgate, or something like that (I don't pay much attention to such things...):

http://i207.photobucket.com/albums/b...P1S48-f-2p.jpg

And here's the amp (A bluapunkt):

http://i207.photobucket.com/albums/b...0003_small.jpg

Those two cost me about $170.

Now on to the box. This time I really splurged.... I got one 4*8 sheet of 3/4 MDF, some wood glue, some carpet and some caulk ('bout $50). Then just went to measuring and cutting...

Here's an intermediate pic:

http://i207.photobucket.com/albums/b...0004_small.jpg


Later on I caulked it. I read online that it needs to be sealed. i also read that it needs to be strong, so I used wood glue and drywall screws on all the seams.

http://i207.photobucket.com/albums/b...0006_small.jpg

As you can see I drilled the holes for the sound port and connector box (the speaker, too which you can't see). Now... Please don't ask me why I put the sound port there... I have no idea... I read somewhere you can really put it anywhere...

Next I went to carpet it. I checked at the nearest audio store and they wanted $20/yard for carpet. I got it at Lowes for $4.50/yard. I bought 4 yards. I used this glue... Very easy to use... spray one side, spray the other, wait one minute, sticks together like concete...

http://i207.photobucket.com/albums/b...0008_small.jpg


Here's some intermediate shots... Please NOTE HERE: I am not a carpet guy, never done this before, EVER. A sharp razor and some patience is all it really took.

http://i207.photobucket.com/albums/b...0010_small.jpg

http://i207.photobucket.com/albums/b...0012_small.jpg


Nearly finished....

http://i207.photobucket.com/albums/b...0014_small.jpg

The stuff I ordered finally came in... so I plugged all that stuff up...

http://i207.photobucket.com/albums/b...0015_small.jpg

http://i207.photobucket.com/albums/b...0016_small.jpg

You may be wondering about the odd shape... look under your seats and you'll understand. I wanted to do two subs, but the middle section was too narrow.

I won't go into the AMP install 'cause I know you know how to do that. I used source and switched from my horns (the compressor is under the left rear corner of the bed) and the Amp sits under the right rear seat.

Needless to say this ROCKS!! All told it cost me about $250, but that included a $20 prototype. Way less than half of the professionals, but I like it.

Here it is under the seat...

http://i207.photobucket.com/albums/b...0019_small.jpg

This project was fun and shot the hell out of some weekend boredom (including making me forget about a birthday...)

[fla_guy]

One awesome write up! Looks good man.

[dani7]

pretty cool how you just went for it.. LOL nice write up

[frostydawg69]

Looks great man. do you have any measurments on the box?

[MMASSgt]

That is the proper hobbyist attitude. Good work.

[AZARDNUT]

Thats a clean looking set up.

[TundraLv]

Looks Good! I'm guessing the sub is facing the rear of the cab? Any pics with the seats up?

[Jer]

Yours looks great and I'm sure adds a lot of sound. Love home built stuff like this.

One thing to keep in mind though is that your buddies store bought JL setup includes a W7 sub which is over half the cost of the whole setup. To compare apples to apples your sub is substantially less expensive. I'm sure for your use though it will work great. I just noticed you commented about not knowing much about them and thought I would give you a heads up on the JL Audio W7 subwoofer. It's a pretty awesome sub.

[Brandon1]

Also another thing to keep in mind is that putting a port in a speaker box requires more than just putting it in. It has to be *tuned* to the speaker and the cuft of the enclosure. Your Rockford manual should tell you how long and what diameter the port should be according to the size of your box.

[HLN A55]

Originally Posted by TundraLv

Looks Good! I'm guessing the sub is facing the rear of the cab? Any pics with the seats up?

Great write-up.

Along with TundraLv-do you have any pics looking at the back seat from the front?

[dragaeran]

Depending on your "tuning" of the port, you can dramatically change the "sound" and perceived volume of the speaker output. Typically, ported boxes are tuned to a specific frequency that is either most common for what the listener likes or the "measured frequency" for an SPL competition or SQL contest.
As for the general listener, you will probably never know the difference as long as you just enjoy all general types of music and never push it to it's limits. Most of us fall into this category......well, maybe I push my a little!?
Anyone know how to get a Pioneer Z2 to go above 40 on the volume meter?? :-)

[bbolton]

Great write up! Clean looking install; you did a hell of a job for a first time-er!

[czechm8]

Interesting! That looks like an awefully big ported box for that sub. Do you know what the port length is, or is it just a 2" hole? Tuning?

[lcdrbrentcarroll]

Thanks for the comments... a few responses.

Measurements: The box fits exactly between the two seat floor brackets, a hair under 30" wide. It's 23" deep. Under the seat it's 5" and then flares to 10" to fit the speaker.

Port location/size/length: After the install, I went through 3 or 4 millions variations of input level, bypass freq, bass boot, port length. You are right, the port length makes a big difference as I ended up cutting it down to 3". It has to be a function of frequency, box volume and gemoetry. Thanks for the info.

Big box/small speaker: You may be right, I dunno. The speaker is rated at 500W, the Amp at 600W and I got it sounding pretty good with a nice "thump." Funny, I am an engineer, but took ZERO time to calculate what would sound best, I based the construction on the fit of the car.

Any-hoo, like I said, it was fun and cheap and again, thanks for the comments.

[txbonds]

Looks nice. Great job. Makes me wish I had a 2nd gen to have all that space to work with.