- 1). Cut four pieces of plywood to the dimension 20" by 24." These pieces will make up the front and back of each PA speaker.
- 2). Cut four pieces to 12" by 24", these pieces will provide the sides of both of your speakers, left and right for stereo sound.
- 3). Cut four pieces of plywood for the tops and bottoms of your PA speakers. These pieces should be 12" by 20".
- 4). Measure the size and shape of the speaker jacks. Cut one hole each in the two back pieces to accommodate the jacks. First drill large holes, then use a jigsaw to complete the holes.
- 5). Route areas on the front piece for the speakers you will use. For a full-range cabinet, route an area for a 15" woofer, a 6" mid-range driver and a 2" square cut for a tweeter. Place the route for the 15" speaker toward the bottom for the best bass response. Place the route for the 6" mid-range above the 15" on either side of the 15" speaker in an offset configuration to save space. You can place the 2" tweeter on the other side.
- 6). Glue the tops and bottoms to the sides of each speaker. Use one 12" by 24" piece on each side of a top and bottom piece. This will make a basic frame for the speaker. make sure to use a 90-degree triangle to ensure that the box has four 90-degree angles at each corner on the inside.
- 7). Nail the back and front onto the frame you have glued together. Allow the glue to dry for 24 hours on the frame before nailing any weight-bearing components to it.
- 8). Insert the speakers into the front and screw them into their respective holes with wood screws. Then wire the speakers into the jack with 16-gauge speaker wire.
- 9). Paint the cabinets or cover them with audio cabinet carpeting or Tolex. Use spray adhesive to secure the material you decide to use, as this will allow the material to withstand the rigors of use and constant movement.
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