Project Category:
Home Theater

Project Level:
Beginner

Project Time:
8-20 Hours

Project Cost:
$100 – $500

Project Description:
This is the very first speaker project that I made for the family for Christmas 2017. My son Daniel and I built it together. He was a real trooper. It has 50 W/Channel. Built with 3/4 inch Pine boards and reinforcements inside. I used Dayton’s KAB-250A amplifier which gives the speaker bar Bluetooth capability, portability with added battery packs, external inputs, and 2 USB Charging ports in the back. I used 4 Audax 3 inch full range drivers and Dayton’s soft dome tweeter (DC28FT-8 1-1/8″ Silk Dome Truncated Tweeter), and 2 XO2W-3.5K 2-Way Crossovers 3,500 Hz. Each side is divided in the box to preserve appropriate dimensional calcs. Two ports in the back along with a volume knob, power input, and that input board. There is much I would redo, but overall I think it is a good first project for a amateur Maker.

I thought a Little U2 Elevation was a good test of the Soundbar Quality. Granted I recorded it with the iPhone, but I hope it somewhat conveys its output and sound. Thanks for checking it out.

Design Goals:
1-Create a great sounding stereo soundbar to place the 40″ LED TV on top of. 2- Have Bluetooth Capability. 3- Optional Battery Power for moving outdoors for social events. 4- Beautiful Natural Wood Appearance. 5- USB charging ports in the back.

Driver Selection:
Four AuraSound NS3-193-8A 3″ Extended Range Driver 8 Ohm.

Two Dayton Audio DC28FT-8 1-1/8″ Silk Dome Truncated Tweeter

Enclosure Design:
External Dimensions 36″W x 4.5″H x 11″D. Center baffle internal.

Two Speaker Cabinet Port Tube 1-13/16″ ID x 2-7/16″ L

Enclosure Assembly:
Assembly was pretty straightforward as the Driver holes we did with hole cutters on the drill press. Assembly was done with a Domino Joiner and Pocket Hole Screws. Screws were installed on the exterior back panel to allow for upgrades and battery removal. I attached the PDF’s for the box and speaker internal components design to this submission if anyone is curious. I also attached a parts list, and specs for the drivers.

Crossover Design:
Two Dayton Audio XO2W-3.5K 2-Way Crossover 3,500 Hz

Tips & Tricks:
I let my son install the AuraSound and Dayton drivers. He did a great job, but we are off a little bit on rotation. Next time draw two lines to align the screw holes. I am installing a grill over the drivers soon, so I am not going to worry too much about the alignment (gives it personal character). I would’ve put the LEDs in the back if I had it to do over. The green one is downright offensively bright under the TV.

Conclusion:
Overall, this was an easy and fun first timers project for me. I appreciated the modularity of the KAB-250A and the add-on boards, charging modules, and LED’s. My son and I built the enclosure, assembled the internal systems, and loaded the drivers and were pleasantly surprised at the great sound of this combination of amplifier and speaker components.

YouTube:

About the Designer:
My name is Scott McGregor from Woodstock, IL. I am a hobbyist who would love to become better at this fun speaker building thing. I am a management consultant by day and a woodworker hobbyist by night.

PDF Files:

275076daytonaudiodc28ft8silkdometruncatedtweeterspecifications

296258_aurasound_ns31938a_specifications

aurasound_ns31938a_3__extended_range_driver_8_ohm

canvas_1

canvas_2

dayton_audio_dc28ft8_11_8__silk_dome_truncated_tweeter soundbar_box_dimensions soundbar_parts_list

soundbar_parts_list

Project Parts List: