Building curved speaker boxes requires knowledge of carpentry and audio equipment. It is a time-consuming process in which a work of art is created that also doubles as a speaker. Curved speaker boxes are usually made of wood and they are customised for your audio needs. The type of acoustic sound you are going for will determine the size and curve of your speaker box.
Measure and cut your wood (cherry or oak), using the mitre saw, to your desired size dimensions.
Hollow out and curve the exterior of your piece of wood using a hand plane. This step may take anywhere from six to eight hours depending on the amount of curve your desire and the dimensions of your speaker box.
Cut out the front or the face of your speaker box using the mitre saw. You will now have two pieces: a front panel and a three-sided box. Create circles in the front of the speaker box to correspond with the size and number of your drivers. Use a handheld jigsaw to create the most accurate and functional circles.
Sand your speaker box and front panel using the belt sander. Be sure to sand both the inside and outside of the box, since a smooth finish is preferable. The actual audio equipment will be added to the interior of the box.
Paint your veneer finish onto the outside of the speaker box. Provide an extra coat of veneer layers to the top and bottom edges of the speaker box to ensure against chipping.
Insert the speaker drivers and crossover into the speaker box. Line up the drivers with the circles in the front panel. You may need to measure to ensure exact placement.
Fill the speaker box with open cell foam. Use the foam to secure the drivers in place and provide the necessary audio dampening a speaker requires.
Screw the 3/4-inch screws into the corners of the front speaker box panel using the power screwdriver. Attach the panel to the box using four to eight screws in each corner and on the side edges. If you want grilles over the drivers, place the grilles on the outside of the speaker box.
Things you need
- Cherry wood or oak wood
- Solid hardwood
- Mitre saw
- Hand plane
- Belt sander
- Handheld jigsaw
- Power screwdriver
- 3/4-inch screws
- Open cell foam
- Speaker drivers
- Audio crossover
- Speaker grilles (optional)