Jack O'Speaker

Hey everyone what's up!

So this is the Jack O'Speaker which is a Bluetooth Speaker crammed into a Jack O'Lantern.

In this case, the Jack O'Lantern is 3D Printed and made out of Orange PLA instead of Pumpkin.

I could make this out of an actual Pumpkin but it won't last long so a better idea is to make the whole thing from Plastic.

Inside this Jack O' speaker, there's a 40W Stereo Bluetooth Amplifier Board connected with a 4 Ohms speaker powered by a 12V Lithium-Ion battery pack.

The goal or motivation for making this Speaker was to prepare a Halloween-themed BT device that can be kept anywhere at the home, and we can play creepy music on it to add some ghostly vibe in the air.

Also, this setup is loud because of the higher wattage the speaker draws as I'm using a super kool speaker which has been salvaged from an old Home theatre system.

In this Instructables, I'm gonna show you guys how I made this project in few easy ways.

So let's get started!

Stuff I used in this built-

3D Printed parts

• Pumpkin Model made from Orange PLA
• Pumpkin Upper part made from Green PLA

Other Stuff

• Audio Module
• Battery Pack 12V 5.2Ah (with BMS attached)
• 3mm LED
• 10K Resistor
• Diode IN5399
• DC barrel jack
• Rocker Switch SPST
• Wires
• M3 Screw x4
• Speaker 8Ohms

Audio Module

Now the Heart of this project is the Audio Bluetooth Amplifier module which is this "XY-P40W".

This Module can work between the Voltage of 5V and 24V but I will be using a 12V Lithium-Ion battery pack to powering this module.

This module runs Bluetooth 5.0 and has dual speaker output.

Also, the output power of the setup I'm using is around 20W which is with a 4 Ohms speaker at a 12V Power source.

It comes with a Volume Adjusting knob but I won't be using that in this project.

I got this module from PCBWAY's Giftshop, link is here- https://www.pcbway.com/project/gifts_detail/Stereo...

Speaker

As for the Speaker, I'm salvaging a great speaker from my old home theater set.

The Speaker I'm using is a 4 ohms woofer and its built quality is just awesome. I have a total of 10 speakers with me so i will be making a bunch of these Pumpkin speakers I guess. (image is attached of the whole home theater system which I bought in 2010)

Anyway, a normal 4 Ohms speaker will work as well, if you want to make this project then you need to edit the mounting holes for the replacement speaker.

The plan here is simple, Jack O'Lantern shape will contain or house the Speaker, Audio Module, and Battery Pack.

I will be adding a switch between the battery and the Audio module for turning the setup ON\OFF.

Also, for charging the battery pack, I will add a DC Barrel Jack with an IN5399 Diode in series and an indicator LED that will indicator the charger Plugged IN.

As for the 3D Printed part, I will be using the generic pumpkin shape and modify it for BT Speaker conversion.

To start this project which involves a Pumpkin Model, I have to model a pumpkin.

Unfortunately, Modeling a pumpkin is a very long process but you know what's easy and really a good tool for this kind of stuff, Tinkercad.

• From the Tinkercad's Part library, I selected the Jack O'Lantern Model and then set its dimensions as required.
• Then I exported the Pumpkin Model from Tinkercad to Fusion360 Directly as both of them are Autodesk products and hence they are connected so we can send any file made in Tinkercad to Fusion360 which is a cool feature.
• In Fusion360, I first cut down the Top side of Pumpkin so I could add a speaker inside it.
• For Elevating speaker position a little bit I added a part between Base Pumpkin Speaker. (later I made this part from green PLA which gives this project nice dual-color contrast)
• AfterFinalizing the Model, I exported its 3mf file for 3D Printing.

As for the 3D Printing settings and color profiles, I used two kinds of PLA in this project.

Actually same kind of PLA but with different color pigments, Green and Orange.

Base Pumpkin is made out of Orange PLA and the Elevation for Speaker is made from Green PLA.

Both parts have the same settings for printing which are these-

• Nozzle used- 0.5mm Nozzle
• Infill- 20%
• Layer Height - 0.2mm
• Speed - 50
• Wall thickness - 1.5mm
• Support required only for Pumpkin Base
• Build Plate adhesion- Raft But only for Pumpkin Base

As for the Electronics of this speaker, we mainly need three components which are as follows.

• Speaker
• Audio Module
• and Battery

Speaker is the 4Ohms Samsung Speaker which is a woofer.

Audio Module is the XY40W Audio Bluetooth AMP and Battery is a custom-made Battery pack rated at 12V 5.2A.

The Battery Pack is made from 3S 3.7V 2600mAh Lith8um ion cells.

A BMS was then added to manage the battery charging and discharging cycles without causing any damage.

My advice here is to get a decent BMS from the market instead of making your own as the Li-ion battery tends to explode or caught fire easily if something goes wrong.

Also, I removed DC Jack and Connectors from Audio Module as the Pumpkin doesn't have much space inside and I have to cram everything inside the less space so by removing these stuff from the PCB it gets easier to layout the Board on one side of the battery pack.

First, we wire the Battery CIrcuit and speaker together with the switch in between according to the given schematic.

Then we add DC Jack to this setup on the Battery by following the given schematic.

DC Jack will be used to charge the 12V Battery Pack.

Also, I have added a Diode in between the positive of the battery and DC jack to limit current a little bit and to connect a 3mm indicator led that will indicate the power plugged In status.

After Connecting the DC jack to the Battery, our basic setup is ready to rock and roll.

But not just yet. We still have to add this whole setup inside the Pumpkin body.

Final Assembly includes these points.

• We first add DC jack and Rocker switch to the base pumpkin.
• then we add the whole Bluetooth + Battery + speaker setup inside the pumpkin and that will be it.

By following the before wiring. I laid out the same wiring inside the Pumpkin speaker.

Then I secured the Speaker with four M3 Screws. These Screws hold the speaker and the middle extension in place with the Lower pumpkin body and the setup was finally completed.

Now, let's test this bad boy by playing some banger music.

Here's the Result-

This setup is perfect but now that it works, the next improvement for V2 would be to make it bigger so I could add LEDs inside this setup that will glow.

Maybe a Music Visualizer can be added to this setup as well for better audio feedback.

we'll see how things turn out but this is it for today folks.

Leave a comment if you need any help regarding this project or my previous projects

And I'll be back soon,

Peace!