to make a simple SEALED box use a router with a plunge bit (3/8 endmills work as well but need a hole drilled first and 1/2 horse router. these also chip wood more. if they are round speakers they have a radius tool. for 6x9 style use the same tools and measure radius and distance on flat. cut the smaller half circles and then the straight line. you then use same router and change bits. recess the speaker 1/4 inch to hide them. use sillicon to seal speaker down before screwing it in. use a nice black cloth streched tight to cover, stapled to back board.

for rest of box just use router and run a square 90 degree the size of front panel and do the edges as well so it fits tight. with the edge recessed you can then drop back in. glue and screw togeather.

buy the terminal connectors from radio shack and drill back accordingly. solder or crimp terminals from speakers to terminal you added or salvaged. take sillicon and seal box with back off as well as around terminal added to the back board. let dry then add cotton batting. ( walmart or craft store thhat sells fabrics) around box. spray adheasive is nice but not required. do same for back pannel. screw on back.

stain or carpet accordingly. car trunk carpet works nice.

just a note on wood. 3/4 mdf or particle board is best for sound (treadmills provide a very heavy duty piece and works great. you can use hardwood as well but it changes tone.

the cotton batting is to allow higher wattage and dampen the sound wave reverb in the box to produce truer sound. it also allows the sound of a bigger box in tighter space and covers up some builder error.



as said above the ohm is important as it can ruin the speaker or stereo / amp. also start low powered and slowly go higher and you can guess wattage. ohm. can be detirmined with a multimeter. wattage is trial and error without some identification. try looking up organ model specs. this can help you figure out the size for the box as well. no less than 2 inches smaller than speaker.

fyi boxes built like this can handle in excess of 5-10k watts if speaker and head unit / amp can handle or produce it so you have no worrys about box being ruined by high wattage. it will out last the speakers.

i have built many like this for home and car use.

hope that helps.