The construction of this subwoofer is pretty straightforward, as long as the panels are precisely cut all you need to do is start with the inner panels and work your way outward. To make sure you’re not met with surprises during construction it is good practice to do a test run first, by putting it together with the help of some tape, before you actually apply glue. This way around you’ll be able to see whether everything fits, or whether some panels need some extra attention. The entire subwoofer is glued together with regular white wood glue and the help of some weights and clamps. To ensure that the all panels are glued in airtight you need to use a sufficient amount of glue, which usually means that it will be forced out of the seams when applying force, this is a good measure of sufficient use of glue.
To add extra weight to the passive radiator it is equipped with a screw on the back which will allow you to add extra weight. Obviously this weight needs to be added so the passive radiator cone doesn't slant or is otherwise obstructed in its movement. We used common 1-mm lead sheet, often used for roof construction on houses for example, and a 82-mm diameter hole cut saw with a power drill to make discs with a perfect center hole. After flattening them out and sanding them down a little, they were spray painted black. You'll need three of these discs to get to 200-grams, but it doesn't hurt to measure the weight before you bolt it on.
The passive radiator with added weight, cut from common lead sheet and painted black.
After the glue has dried and settled, which usually is after about 24-hrs, you can start with the finish of the subwoofer. If you’re looking for a professional finish you’ll need to sand it down several times and apply filler and primer to make sure any seams and cracks are covered and the surface is smooth and level. Then it is time to apply the final layers of paint, we opted to spray paint the subwoofer using automotive spray paint, which is both durable and tough, and when applied with care and attention results in a perfect result. Obviously you can also opt to finish the subwoofer by applying real wood veneer or by use of a paint roller and regular paint or any other finish that you find appealing.
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