How to Construct a Sub Box

Box Minus the Front

• 1

  Spread glue to the 12 1/2-by-13 3/4-inch area of one of the 12 1/2-by-13 3/4-by-3/4-inch MDF. Set the other piece on top so all four sides are even. Clamp them together with the C-clamps. This is the front of the sub box.

• 2

  Place the 1-by-12 1/4-by-3/4-inch MDF on the worktable along with the 1 3/4-by-12 1/4-by-3/4-inch MDF. Put some glue on one of the long edges of the 1-inch wide pieces. Clamp them to the 1 3/4-inch pieces so the inside of the L-shape is 1-by-1-inches. These are the ports for the subwoofer box.

• 3

  Set the 11-by-12 1/2-by-3/4-inch MDF on the worktable. Make a mark at 1-inch from a corner on the 11-inch edge and from the same corner mark 1-inch on the 12 1/2-inch edge. Repeat this on the opposite corner of the 11-inch edge.

• 4

  Put the blade of the combination square on the marks and draw a 1-inch line. This produces a 1-inch block in the corners on the same 11-inch edge. Cut the blocks out with jigsaw. Set the terminal cup on this piece in a desired location and trace its pattern onto it. Drill a hole inside the pattern with a 3/8-inch drill bit. Slip the jigsaw blade into the hole and cut out the pattern. This is the back of the box.

• 5

  Remove the clamps from the ports once the glue is dried. Glue one end of the ports and clamp them to the back on the notches with the 24-inch bar clamps.

• 6

  Run a bead of glue to the 15 3/4-inch edges of the 11-by-15 3/4-by-3/4-inch MDF. Place them between the two pieces of 15 3/4-by-13 3/4-by-3/4-inch MDF. Clamp the pieces together with the 24-inch bar clamps.

• 7

  Take the clamps off the box and ports once the glue is dry. Caulk the corners inside the box with latex caulk. Apply glue to the four edges of the back and set it inside the box even with the edge of one opening. The ports will be inside the box. Clamp the back in place. Remove the clamps when the glue is dry.

Front of the Box

• 8

  Remove the clamps from the front piece of the box. Place a straightedge diagonally from corner to corner and draw lines forming an X. This marks the center point of the front. Set the compass on 4 5/8 inches.

• 9

  Stick the point of the compass in the center point of the front and draw a circle. Drill a hole inside the circle with a 3/8-inch drill bit. Slip the jigsaw blade into the hole and cut out the circle.

• 10

  Apply glue to the front edges of the box. Set the front piece of the box on the box and clamp it in place with 24-inch bar clamps.