Bluetooth Speaker Housing and Lid

This is a wooden housing that I made to learn about woodworking and using the lathe. I created it for a Bluetooth speaker, but it could be used to contain pretty much anything you want.

Materials

For the Housing:

• ~70 inches total length of hardwood 1 inch width (The strips can be as shorter as they will be cut into 2 7/8 lengths)
• Wood Glue
• Sandpaper of varying grit
• Rubber Bands
• Extra piece of wood for attaching to lathe
• Screws (slightly shorter than scrap wood)
• Polyurethane finish
• Rubber stops for the bottom

For the Lid:

• Speaker cloth (enough to cover the entire top of your housing- probably about 5"x5")
• Hot glue
• Small magnets
• Super glue
• 1/8" piece of Baltic birch (approximately 5"x5")
• Bolts to secure speaker

For the Speaker:

• Power Supply- AC to DC $9
• Female Barrel Jack Connector $.54
• Battery Charging Board with Battery Protection BMS 5V Micro USB 1A 186 50 Charge Module $.35
• Micro 4.2 Stereo Power Amplifier Board Audio Module 5VF 5W+5W $7.99
• Step up Converter DC Voltage Regulator Voltage $1.30
• EEMB Lithium Polymer Battery 3.7V 1400mAh 103440 Lipo Rechargeable Battery Pack $5.99
• Gikfun 4Ohm 5W Full Range Audio Speaker Stereo Woofer Loudspeaker for Arduino Replacement (Pack of 2pcs) EK1949 $12
• 22 Gauge Wire

Tools Used

• Table Saw
• Miter Saw
• Belt Sander
• Lathe
• Band Saw
• Laser cutter

Using the table saw, cut the wood into strips of 1 inch width. Then cut the strips at 30 degree angles on the miter saw, with the long side measuring 2 7/8. You should end up with trapezoidal shaped pieces as shown.

Glue the pieces into groups of six to form hexagons. Use the rubber bands around the outside in order to secure the piece while the glue is drying.

Stack each hex on top of each other and glue. You can stagger them slightly so as to minimize the prevalence of the seams. I also glued a waste block to the bottom in order to attach the piece to the lathe.

Attach the chuck to the bottom of the piece and mount it on the lathe. Using the tool, slowly remove small amounts of material until the piece is circular, then remove additional material to achieve the desired shape. I then used the parting tool to make small grooves in the material.

Go through each of the grits, eliminating any imperfections in the wood until you have achieved the desired results. I started at 60 grit and progressed through each one, ending at 600.

Use the parting tool to separate your piece from the scrap block, but leaving a small amount of material so it does not fly of the lathe. Then turn the lathe off and use a hand saw to cut the last inch of material.

Use the belt sander to smooth out the bottom and remove the remaining material from the scrap block. Then use the laser cutter or a drill to make a hole in the bottom for the power switch. Attach the rubber stops around the power switch so that the piece sits flat. I then finished it by painting on a clear polyurethane.

I used the laser cutter to cut a circular lid with a hole in it for the speaker to fit. I then drilled holes and bolted the speaker into the lid. I also drilled a hole next to the speaker to put the barrel jack in.

I cut a piece of speaker cloth of sufficient size to cover the lid of the speaker and then used hot glue to secure it. I then made a small slit in the speaker cloth over the hole for the barrel jack so that I could put the barrel jack in.

Using the drill press, I made three small recessed holes in the top of the speaker housing so that the magnets would sit flush with the top. I then glued each magnet in place with super glue. I attached the corresponding magnets to the bottom of the lid, being sure to check the polarity of each before super gluing them.