Re*Sci*cling: Speakers * *

Part A Prepare Voice Coil

A1. Wind Coil on bobbin (See Part D Coil Winding instructions). A2. Use an emery board to remove of the shiny coating from the ends of the coil wires. A3. Use soldering iron to flow solder onto all the ends of the coil and connecting wires.
Solder Bowl Coil Wires Coil

A4. Take the end of each connecting wire near the knot and wrap the tip of one of the coil wires tightly around it. A5. Heat the joined wire ends with a soldering iron until the solder flows to connect them. A6. With the wire side down, put a circle of hot glue around the top rim of the bobbin (not near the center). Quickly glue the bobbin to the underside of the bowl, centered around the hole in the base.

Knot Connecting Wires

Re*Sci*cling: Speakers * *
Part B Prepare Speaker Frame & Cone
B1. Place 1 nut & 1 washer completely on the bolt, pass the bolt thru the top of the jar caps and fasten it in place with another washer and nut. Hand tighten. B2. Push modified Bic pen tip into one end of the white plastic tubing until the colored part of the pen reaches the end of the tube.
Bowl Magnified View
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B3. Quickly remove pen and push the red tip end of magnet into widened end of tube until the entire red tip is inside the tube. B4. Slide tube onto the bolt until the magnet contacts the end of the bolt. B5. Trim the bowl so that it is only 1 tall. It should then be smaller in diameter than jar rim. B6. Use attached template to mark the location for 3 holes, evenly spaced around the bowl rim B7. Use a hole punch to make the holes about 1/8th inch from the bowl rim.
Jar

Magnet Tube

Bolt

Washers and nuts

Lids

Hole

Re*Sci*cling: * * Speakers
Bowl Marking Template

Hole

Hole

Re*Sci*cling: Speakers * *
Part C Assemble Speaker
C1. Untwist the longer ends of the connecting wires. Put the wires into the jar and pass each one thru one of the holes near the lid. C2. Pull the wires until the knot is against the inside jar wall. Loosely tie the wires together with another knot outside the jar. C3. Insert small rubber bands into the 3 holes in the bowl & pull the inside loop thru the outer loop. C4. Place bowl inside jar so that the magnet fits inside the bobbin/coil. C5. Pull the inner loops over the rim of the jar, and fasten in place with small binder clips. C6. Adjust binder clips so that magnet is centered inside the coil. C7. Adjust the height of the bolt so that the tip of the magnet is inside the coil, but the tubing does not touch the bobbin. This may require a different bolt or number of washers. C8. Twist the connecting wires together and solder each end to one of the contacts on a battery clip.
Battery Clip Bowl Coil Magnet Rubber Bands