jikhead

OK, so here's what I've got going on...

I bought a Pioneer TS-SW2501S4 and it's mounting depth is 3" and the recommended air space is 0.45 cu.ft. (min 0.35 & max 0.7). Pioneer's manual also recommends 3/4" MDF, which is what I bought.

So I've cut out varies sizes to try and contour the wheel here. I did it to try and get as much cubic air space as possible. Now, just looking at it when I stack them...I'm pretty certain there's going to be at least the min cu.ft. The manual does state the figures above include the speaker displacement. You wouldn't think so when you place the speaker up to it. But if you visualize a 0.5 cu.ft is 6"x6"x6", there will be this much space...just not in a square shape of air..but all around the speaker. It would definitely be easier to cut all the pieces the same size, and then leave the top piece wider. If I do another, I may attempt this to just to see. I've got enough MDF left to do 2-3 more boxes, so I may do some experimenting and build some more. So, you can see that they are staggered in size from bottom to top. When stacked, it somewhat resembles the Bose sub in a way. I will provide the measurements of each board later, as all this is at the shop at work. Now, I used a Rotozip w/circular cutout tool. Not all of my cuts are completely circle and perfect. I made some cuts that were slightly too big, and it needed to be trimmed. It's too hard after the fact, using the Rotozip, so I ended up doing all my trimming work on a bandsaw. When I used the bandsaw, there goes my perfect circles. So now, I plan to take board #2, cutout the inner piece of it, leaving a 3/4" ring. I'll repeat this as I work my way up the boards. Each board up will have a ring slightly larger. This is because the inner diameter rings will be flush; the outer diameter will not since the boards are tapered and staggered in size. Hope you follow me there. I'll repeat this until I get to the top #6 board. My Pioneer speaker package came with a cutout template built into the cardboard packaging. This will be used to make the speaker cutout. Next will be using liquid nails to glue each piece together, and use sheetrock screws as well. You'll notice that the screw will not go all the way down into the MDF board, leaving an air gap when stacked. I went back to Lowe's and didn't see anything else that would really help. So, I will drill out a little depth for the screw head to sink flush/or below the level of the MDF surface.

I'll pick back up tomorrow. I plan to cut something in the top board so you can grab it and pull it out. Don't know whether a hole for your hand to fit in, or attach rope, or what yet. I also will carpet it, and put a speaker terminal cup. This will probably have to go on the bottom.

Also, there's probably going to be an issue with the box rattling. Another member mentioned this with his. If you think, when the sub is bumping, I foresee it maybe jumping up and down a little inside the wheel. The wheel may need to get some foam or something too, to keep it from moving around.