DIY project speaker moulds

Keeping in-line with my theme on the sound system I decided to build a moulding for the speaker, so I can attach them to the wall. this was a collaborative effort between myself and ophelia sookhan over at Do It Yourself by Ophelia.click here to see more from her.

How to make molding for your speaker using Styrofoam and glue.

In this tutorial we will be using the boss CH6500 6.5 2 way speaker; however any speaker can be used.

Step 1

First you will need to get some Styrofoam. In this case this speaker is about 2 inches thick; I was only able to find 1 inch thick Styrofoam board. So we will have to join them together, to get the appropriate thickness. In the package for the speakers you will receive a speaker grill to cover the project; we will be using this to get the shape and size for our cutout. So to begin place the speaker grill over the Styrofoam and using a marker draw around the plastic grill. Repeat this step twice for each speaker.

Step 2

Now using the utility knife cut out the shapes you just made. Note: make sure the utility knife or whatever you are using is long enough to reach trough the Styrofoam board or you will have a hard time getting the circle out.

Step 3

Now there is about ½ an inch of metal surrounding the edge of the speaker. Normally this space is used to drive screws trough to mount the speaker to a surface. We will be using this space to mount the speaker to the Styrofoam. So our next step is to measure a smaller circle inside the first one leaving space for the mounting area. You should be left now with something that looks like a wheel or basically a ½ inch thick circle that’s hollow in the center. This will be the top piece.

Step 4

Now looking at the speaker you will realize that it gets gradually smaller towards the bottom, at the bottom of the speaker is a large magnet. For the lower ring we only need to make a hole large enough for the magnet to fit trough. You should be left with a similar ring like in step 3 but the hole will be smaller.

Note: before we proceed to the next step make sure everything fits together properly and the speaker fits when both rings are placed together.

Step 5

Providing all steps was followed and the speaker fits properly. You can now glue the two rings together. You can use a hot glue gun, contact cement or most craft glues (not paper glue), To achieve a good bond. Let sit for a few minutes to dry, the time for this step will depend on the type of glue used.

Step 6

Now that the glue has dried we can move on to mounting the speakers into the mold. Now in the package you should have receiver some washers for the screws to go through. We will be using these to mount the speaker to the Styrofoam as screws may not hold properly to Styrofoam alone. Put the speakers in the rings and then place the plastic grill on top. Mark out where the screws will be placed. Now using those markings insert the washer’s right under the screw holes/marks about a ½ an inch under the surface, or just enough to prevent the screws from coming out easily.

Step 7

Make a small hole in the side to allow the speaker wires to run through, and then assemble the whole thing. Place the speaker in the center followed by the grill on top, and then screw them together. Clean up any rough edges and you’re done.

Optional: in this tutorial I covered the project over in a carbon fiber vinyl. This is not necessary but it will make the project look better.