Vernon Ten

Vernon Ten


Steve L

Project Category:

Project Level:

Project Time:

20+ Hours

Project Cost:



Project Description:

Sealed powered sub for home use (mostly music)

Design Goals:
Sonically and visually complement my 1980s-vintage Boston Acoustics HD7 main speakers

Driver Selection:

Dayton Audio DCS255-4 10″ Classic Subwoofer 4 Ohm

Enclosure Design:

Simple 0.63 cu.ft. sealed speaker chamber partitioned off from the 100-watt class D panel amp. The basic box consists of 3/4″ MDF panels assembled with wood glue and simple butt joints. Exposed MDF edges were coated with spackle and sanded smooth, then the box was primed with oil-based primer and painted with black hammered-texture spray paint. I applied walnut veneer to the top and sides with 1/2″ walnut dowels as decorative accents. The mitered grille frame is also walnut. I finished the wood with sanded-in tung oil/varnish mixture. I used a minimal amount of Acousta-stuf polyfill fluffed out and attached to the inside back panel with spray adhesive. Three cheap but sturdy rubber feet from Amazon are bolted to the bottom. Finally, I used automotive RTV silicone where the speaker wire passes through the box, and around the speaker flange, to guarantee an air-tight space.

Crossover Design:


Tips & Tricks:

I replaced the spring-loaded speaker terminals on the DCS255-4 with M4 screws and nuts for a more reliable (I hope) long-term connection. And the black foam grille enhances the retro look.


Never having built any kind of speaker before, I had no idea whether this would even work. To my surprise, the darn thing produces tight, natural-sounding bass. So far, everything I’ve thrown at it, from pop to rock to jazz, sounds excellent.

About the Designer:
Amateur woodworker and music lover with a shoestring budget

Project Parts List:

Part #DescriptionQty.
295-202Dayton Audio DCS255-4 10″ Classic Subwoofer 4 Ohm1
300-805Dayton Audio SPA100-D 100 Watt Class-D Subwoofer Plate Amplifier1
260-317Acousta-Stuf Polyfill 1 lb. Bag Speaker Cabinet Sound Damping Material1
260-519Parts Express Speaker Cabinet Grill Foam 19″ Wide x 31″ Long x 3/8″ Thick Black1

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