How to Make a Speaker Cabinet with a V Fold Design

Stand the first and second plywood pieces that measure 25 inches by 24 inches on their sides so that the 24-inch sides stand upright. Place these standing pieces of plywood into a V-shape. Repeat this step with the third and fourth plywood pieces that measure 25 inches by 24 inches.

Set the miter saw angle to 60 degrees. Place the first piece of lumber flat on the miter saw. Turn on the miter saw and cut the first piece of lumber so that one of the corners makes a 60-degree angle. Feed this piece of lumber through the miter saw slowly so that one of the corners on the entire length of the piece of lumber makes a 60-degree angle. Repeat this step with the remaining pieces of lumber.

Place the 60-degree angle corner of the first piece of lumber inside the center of the V-shape created by the first and second pieces of plywood measuring 25 inches by 24 inches. Butt the pieces of plywood together so that the piece of lumber and the two pieces of plywood make a solid corner. Repeat this step with the second piece of lumber and the third and fourth pieces of plywood measuring 25 inches by 24 inches.

Drill two holes – one at the top, one at the bottom – through both the edge of the first piece of plywood measuring 25 inches by 24 inches, and through the first piece of lumber. Drill two holes – one at the top, and one at the bottom – through both the edge of the second piece of plywood measuring 25 inches by 24 inches, and through the first piece of lumber. Replace the drill bit with the screwdriver bit. Insert a cabinet screw into each hole, and tighten the screws into the holes so that the pieces of plywood are fastened securely to the piece of lumber. Repeat this step for the third and fourth pieces of plywood measuring 25 inches by 24 inches and the second piece of lumber, respectively.

Stand the first piece of plywood measuring 24 inches by 24 inches on edge, and place this piece of plywood crosswise into the space created by the first and second 25-inch by 24-inch pieces of plywood. Align the 24-inch by 24-inch piece of plywood between the other two pieces of plywood so that there is a 1-inch lip between the ends of the 25-inch by 24-inch pieces of plywood and the joint where the 24-inch by 24-inch piece of plywood touches the other plywood pieces. Insert the third and fourth pieces of lumber on the inside angles where each piece of plywood meets. Repeat this step for the third and fourth 25-inch by 24-inch plywood pieces and the second 24-inch by 24-inch plywood piece. Attach each piece of plywood to its respective piece of lumber as outlined in step 4.

Place the first speaker over the outside center of the first 24-inch by 24-inch piece of plywood. Trace the outline of the speaker face over the center of the first 24-inch by 24-inch piece of plywood. Repeat this step on the second 24-inch by 24-inch piece of plywood. Use these outlines to cut out a speaker hole on each 24-inch by 24-inch plywood face using the coping saw.

Place the first speaker terminal plate over the outside center face of the first 25-inch by 24-inch piece of plywood and trace the outline of the terminal plate on the piece of plywood. Trace the speaker terminal plate on the outside center face of the fourth 25-inch by 24-inch piece of plywood. Use these outlines to cut out a speaker hole on each respective plywood face using the coping saw.

Insert the first speaker terminal plate into the hole in the first 25-inch by 24-inch piece of plywood. Insert the second speaker terminal plate into the hole in the fourth 25-inch by 24-inch piece of plywood. Drill through the mounting screw holes on each terminal plate into the plywood and attach each terminal plate to its respective plywood surface using the wood screws.

Insert the first speaker into the hole in the first 24-inch by 24-inch piece of plywood. Insert the second speaker into the hole in the second 24-inch by 24-inch piece of plywood. Drill through the mounting screw holes on each speaker into the plywood and attach each speaker to its respective plywood surface using the wood screws.

Cut two pieces of red wire and two pieces of black wire using the electrical pliers. Each wire should be long enough to reach from the back of the terminal plate to the speaker and still have at least 3/4 of an inch of slack. Strip 1/2 an inch of insulation from the ends of each wire.

Use the soldering iron to solder one end of the first black wire to the black terminal on the backside of the first speaker terminal plate. Solder the other end of the first black wire to one of the speaker terminals on the first speaker. Solder one end of the first red wire to the red terminal on the backside of the first speaker terminal plate. Solder the other end of this wire to the remaining terminal on the first speaker. Repeat this step with the second set of wires, the second speaker and the second speaker terminal plate.

Measure the open gaps at the top and bottom of the speaker cabinets. Use the miter saw to cut the remaining pieces of plywood to size to cover these gaps. Place each cut piece of plywood into place and drill a hole through each corner of the loose pieces of plywood where each piece touches the pieces of lumber inside the cabinet. Place a cabinet screw into each hole and tighten each screw to secure the plywood pieces.

Place the speaker cabinets face to face so that the speakers face each other and so that the speaker terminal plates are at a 90-degree angle to each other on the outside of the cabinet. Place the piano hinge on the center of the edge of the speaker cabinets; this hinge should be at the corner where the pieces of plywood containing the speaker terminal plates meet. Drill into these pieces of plywood through the mounting holes on the piano hinge and attach the piano hinge to the plywood pieces using the wood screws.