instructables

DIY Active Subwoofer

by Donny Terek

Hi everyone! Thanks for tuning in to this project of mine, I hope you'll like it and perhaps try to build it yourself! As
always I have included a detailed list of modified plans, a wiring diagram, product links and much more for your
information on the build. I encourage you to check my video first before diving in to the build. Let's get started!

https://youtu.be/Kh8GEj95YDI

DIY Active Subwoofer: Page 1

Step 1: Design Goals and Plans

The main goal for this project was to build a
subwoofer that would play pretty low and would have
an integrated amplifier capable of powering two other
speakers all cramped inside a relatively compact
enclosure. Fiddling around with various woofers in
winISD I have decided to go with a Tang Band woofer
and a 2.1 amplifier for best results. As you can see by
the graph, the enclosure is tuned to 43Hz and has an
F3 of around 37Hz which is pretty amazing
considering the price of the woofer and the compact
enclosure that it needs. Of course it will not play that
low cleanly due to port noise and possible chuffing
but will still perform great.
As you can see below, I have attached a set of plans,
metric and imperial for all needs. You will also find
the template for the control panel in the end of the
plans which you can print out and glue to a piece of
wood to have an accurately made control panel. Feel
free to download the plans and the wiring diagram for
your personal use. I would love to see how your
project turned out!
Note that I have modified the plans therefore the
speaker may look different than in the video. I have
modified the plans to use less components and be
easier to build with an overall better design.

Download
https://www.instructables.com/ORIG/F1K/Y772/JV2R8V7G/F1KY772JV2R8V7G.pdf
…

DIY Active Subwoofer: Page 2

 https://www.instructables.com/ORIG/F5H/YSD6/JV2R8V7K/F5HYSD6JV2R8V7K.pdf
… Download

Download
https://www.instructables.com/ORIG/FRF/4L5Z/JV2R8V7M/FRF4L5ZJV2R8V7M.pdf
…

Step 2: Parts and Materials

You may have noticed that there are less components in the wiring diagram compared to the video. I did so to
reduce the number of the components used and simplify the overall build process of the subwoofer. I have also
used a similar amplifier that has the Bluetooth built in so that you don't need a separate module for that. Here you
will find the complete list of parts and tools used for the build. Note that the parts can be ordered internationally.

COMPONENTS:

Woofer - https://bit.ly/33a9D4L or https://ebay.to/2Z1xlOB

24V DC Power Supply - https://bit.ly/34h72Ge
2 of there ports glued end to end - https://bit.ly/2XNRNkC
2.1 Amplifier - https://bit.ly/2vylk5K or https://bit.ly/2pGHl35
AC Socket with Switch - https://bit.ly/2szORhs
Banana Connector Sockets - https://bit.ly/2DxtG1x
Audio Input Jack - https://bit.ly/34F8eDZ

BITS and PIECES:

Spade Connectors - https://bit.ly/2OBL2kg

Gasket Tape - https://bit.ly/2DDlU6g
Rubber Feet - https://bit.ly/2rkXvQo
M4X16 Screws - https://bit.ly/2OzkX4h
M2.3X10 Screws - https://bit.ly/2rmLkCj
M3X4 Threaded Inserts - https://bit.ly/35LA6X0
Brass Standoffs - https://bit.ly/2ss6dwv

TOOLS:

DIY Active Subwoofer: Page 3

 Multimeter - https://bit.ly/35QJQPN
Hot Glue Gun - https://bit.ly/37U9CVh
Soldering Iron - https://bit.ly/2OByoR7
Wire Stripper - https://bit.ly/2XZ9kI8
Cordless Drill - https://bit.ly/35SfH2B
Jig Saw - https://bit.ly/2OCt40V
Drill Bits - https://bit.ly/2KHTEn6
Step Drill Bits - https://bit.ly/37uUPQz
Forstner Bits - https://bit.ly/35snpjW
Hole Saw Set - https://bit.ly/34cTlZj
Wood Router - https://bit.ly/2rj2lNI
Roundover Bits - https://bit.ly/2OYaDTw
Center Punch - https://bit.ly/2OzuhVG
Sanding Sponge - https://bit.ly/35sQJ9T
Solder - https://bit.ly/2XNOUSt
Flux - https://bit.ly/33eXs5I
Helping Hand - https://bit.ly/2P4QOK7

The main building materials that I used are 12mm (1/2"), 6mm (1/4") MDF boards for the enclosure and 4mm (1/8")
plywood for the control panel.

DIY Active Subwoofer: Page 4

Step 3: Let's Start the Build!
Once you got the plans printed out we can start the
build. As you can see I am using a table saw to
accurately cut the MDF pieces out but I know that not
many people have an access to a table saw.
Therefore you can also use a jigsaw to roughly cut
the pieces out and sand them down later and perhaps
use a bit of wood filler to get the edges as smooth as
possible.
To cut out the piece for the amplifier to go through, I
DIY Active Subwoofer: Page 5
first marked the location of where I need to cut out
and drilled four holes in each corner, making sure to
only drill halfway through on each side to avoid
tearout. I then took a jigsaw and cut as close to the
line as possible. No need to be exact here, it is only
important that the amplifier support panel sits nicely
on the edge. I also cut a hole for the port using a
circle cutting jig on a router but you can use a 64mm
(2 1/2") hole saw so that the port sits snug.
Step 4: More Cutting

Once the side panels were cut I glued the the port in
place. Here I am using a PVC pipe as a port since I
did not have the proper one on hand therefore I glued
the port in place before assembling and painting the
enclosure. You should use these ports and glue both
of them end to end. Make sure you insert one first
through the hole on the side panel and then glue the
other port to the first once you have finished the
enclosure in your desired paint or material.
I also cut the hole for the woofer with a recess to flush
mount the woofer but you can simply cut the hole with
a 127mm (5") hole saw and not worry about the flush
mounting.

DIY Active Subwoofer: Page 6

Step 5: Glue Up!
A self-explanatory and satisfying step - gluing the
enclosure together. Use plenty of glue on the sides
and make sure that the edges are square. Note that I
have glued port supports on the bottom of the
enclosure which I have not included in the plans - that
is one more thing I have redesigned in the final plans
so that there is less cutting and the power supply can
be mounted on the bottom instead.
Clamping the enclosure together is recommended for
DIY Active Subwoofer: Page 7
best adhesion while the glue dries.
You have also probably noticed that I have glued the
back panel support pieces along the back edge of the
enclosure but since I have redesigned the speaker,
you will need to cut a larger back panel and skip the
panel support pieces and screw the back panel
directly to the enclosure.
Step 6: Sanding and Smoothing

Once the glue has fully dried I took an orbital sander
for a quick job of sanding the enclosure and getting it
ready for paint. A sanding block can be used as well
but will take much more time and effort so use any
help you can to speed up the process.
Once the edges were smooth I took the enclosure
and rounded over the edges on the router using a
roundover bit. It turned out really nice with a nice
radius all around the edges. Sandpaper can be used
instead for a similar result.

DIY Active Subwoofer: Page 8

Step 7: The Back Panel

Notice that the back panel sits differently than in the
build plans above. In the redesigned plans you can
see that there are no panel support pieces,
simplifying the build process so that the back panel
can be screwed directly to the enclosure.
I have decided to drill countersinks on the back panel
so that the screws sit flush. I then placed the back
panel in place and drilled the screw holes. Make sure
you drill with a smaller drill bit first all the way through
and then use a larger drill bit only on the back panel
so that the screws don't bite into the back panel but
only clamp it in place.
Holes were then drilled for the AUX input jack and the
speaker terminals. I also drilled the holes for the
rubber feet and placed 4 screws on the bottom to
serve as stands while painting.

DIY Active Subwoofer: Page 9

Step 8: Preparing for Paint

To prepare the MDF for painting, I made a mixture of 50/50 wood glue (Titebond III) and water and brushed it on
the surface letting it cure overnight. This makes the surface hard and great for spray painting later. Once the glue
mixture has dried I lightly sanded the enclosure once again to get it ready for painting. Before spray painting I
wiped the enclosure with a solvent to remove any oils or residue that may have been left on top.

DIY Active Subwoofer: Page 10

Step 9: Applying the Paint

I applied a few light coats of grey primer on the surface. Once the primer has fully dried I sanded it with a 600 grit
sanding sponge for better paint adhesion. I recommend wiping the surface once again with solvent to remove any
oils before painting the color.

I used matte black spray paint for the top color coat, making sure it fully dries afterwards. I am using a heating
lamp to speed up the process.

DIY Active Subwoofer: Page 11

Step 10: Making the Control Panel

To make the control panel make sure you download
the plans placed above and use the last page to cut
out a template. Double check with a ruler that the
measurements are correct on the template once you
print it out. You may need to resize the image to get
the correct size.
piece. Mark the holes with a center punch and use a
small drill bit to drill all the holes first. Then gradually
use larger drill bits where needed to avoid tearout.
Once the holes are drilled take the template off and
sand it smooth. I also applied clear coat on the panel
for a nicer finish.

Simply cut out the template and glue it to the plywood

DIY Active Subwoofer: Page 12

Step 11: Mounting the Amplifier

Take the finished control panel and mount it to the amplifier. I have also soldered a green power indicator LED and
pushed it in from behind. I then placed the threaded inserts in the amplifier support panel and glued it in place on
the ledge of the enclosure making sure that the triangular pieces are also glued in place. I then pushed the
amplifier in place, screwed it in from the inside and drill the holes for the screws.

DIY Active Subwoofer: Page 13

Step 12: Last Steps

Just a few more things left to do and we have a finished active subwoofer! I am placing a strip of adhesive foam
around the edge of the enclosure to make it airtight once the back panel is screwed in place. Same goes for the
control panel opening. Once that is done I mounted the speaker connectors and screwed the back panel in place.
Don't forget to add the rubber feet on the bottom!

DIY Active Subwoofer: Page 14

DIY Active Subwoofer: Page 15
Step 13: Mounting the Woofer

Probably my favorite step of this build is mounting this beefy woofer in its place. For that put it in place first and
used a hole punch to mark the holes for the screws. I then took the woofer out and drilled the holes through the
panel. Using the same adhesive foam tape to make sure the woofer sits sealed against the edge. I ten connected
the woofer to the amplifier and screwed it in place. Placing the amplifier knobs finishes the build.

DIY Active Subwoofer: Page 16

Step 14: Finished!

We can sit back and admire the little subwoofer that we have built. Just plug in the power cord, turn on the switch
and use your preferred method of audio input - whether it is through an aux cable or Bluetooth. The Bluetooth
connection is instant and stable, providing great sound and performance.

Step 15: Final Thoughts

I am more than happy this subwoofer turned out. It
packs a punch and is definitely powerful enough for
home use. It can also output plenty of power to
various different speakers for the best listening
experience.
I hope you liked this project and perhaps learned
something new! My hopes are that you will give this
build a try yourself and post it at the end of the
Instructable so that me and others can admire your
work! Feel free to post any questions or comments
down below, I will try my best to answer them.
Thank you for tuning in to this project of mine and I
will see you on the next one!
- Donny

DIY Active Subwoofer: Page 17

what is the small pad for the power supply and the amplifier sound connect and the jack ?

nice work and thanks for the drawing

wow i must try this thank you

Great job, Thanks! Really good stuff!

Great project. I think I'd look for a more efficient sub, although all the other specs, especially Xmax
look great.
Thank you! I chose this sub to be able to use it in a small enclosure producing great results.

Thanks for your thorough documentation!

My pleasure as always!

Great job! Thanks for sharing the tips and tricks that take a build to the next level!

Thank you so much!

Hi, what a great looking project with a nice clear set of build instructions.
Can you please explain ,what is the purpose of the ports and the piece of pvc pipe? is it for
ventilation? Thanks for a great job!
Hi, thank you so much!
The purpose of the ports used in many speakers is to improve the efficiency of the low frequencies
produced by the speaker. Generally speaking, it helps most speakers play into lower frequencies.
The length and width of the port needs to be calculated according to the speaker used in the
enclosure.
I hope that answers your question!
NICE WORK!!!

Thank you!!

Very nice project!

From your building skills to your video production and presentation, you seem to have a very
disciplined and methodical approach to everything you do and it shows. Well done!
Thank you so much! That truly means a lot to me :)

DIY Active Subwoofer: Page 18