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Lutkeveld

Boominator Buildlog [DIY audio]

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Posted · Original PosterOP

Welcome to the Boominator buildlog.

 

For the people that are not familiar with this design, a quick rundown:

It is an open-source design DIY Boombox optimized for the best and loudest sound possible in free-field listening.

Main components are 4 pro-audio woofers mounted magnet to magnet, 4 tweeters, one SLA battery and one high efficiency class-D amplifier.

 

Without further ado, our cardboard mockup:

15744508077_aec3b419c5.jpg

The small holes are for the Monacor MPT-001 piezo tweeters, the big ones are for the P.Audio HP10W woofers.

There will be a removable middle compartiment where all the electronics are located.

 

After thinking everything out we went to the local hardware store and got our wood:

15308057894_f5f1796b6d.jpg

It's FSC certified 12mm 9-ply plywood. Very strong stuff.

 

The result of a dry testfit

15742968780_50b76ffa4e.jpg

As you can see, each cabinet has a centerbrace. The woofers will be mounted magnet to magnet (bipole).

The magnets will be glued to the centerbrace to ensure a rigid structure.

 

And with the top on it: 

15744232789_23493d2a2f.jpg

You can clearly see where the middle compartiment has to slide in.

 

We're planning on carbonwrapping the electronics module front and back.

15308051964_3feb687c8a.jpg

This is a test piece, but you get the idea :)

 

Next stage: construction. Stay tuned/subscribed :)

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Followed.


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Posted · Original PosterOP

Cutting the centerbraces:

15929631922_acf57d3292.jpg

 

One for either side:

15904484086_62df5bb043.jpg

 

Draw the side handles, which double as bass-reflex port

15308039494_bbfdaa27e0.jpg

 

Cut it out with the jigsaw

15928322071_0972026dde.jpg

 

Glue it to the sides.

15928318111_4d1d753928.jpg

 

You don't want square handles, you wan't it nice and rounded so it won't hurt your hands.

15744251859_2e62bacdc5.jpg

So you take a router

 

And round-over the edges

15930263405_6be4a1c6e0.jpg

 

To be continued...

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Posted · Original PosterOP

Me and my friend had a lot of fun unboxing today. We are in possession of most of the things now. 

Orders came from eBay, Bax-Shop and Accusafe, we still need to order at Conrad.

We first need to recheck some measurements so we can purchase the right filter components.

 

To kick things off, 4 P.audio HP10W woofers, 95db/w/m, 200 watt power handling.

15753207717_76373a388f.jpg

They scream quality

 

Backside, just look at them ;p

15316707164_30ab280998.jpg

 

The Monacor MPT001 Piezo tweeters

15319335273_34a7ea70ab.jpg

 

From left to right: battery, power supply, amplifier, battery protection

15751674850_ba73e04fe9.jpg

-Battery: 7.2Ah Sealed Lead Acid battery from CSB

-Power supply: 12v 3A MeanWell. Man, this thing feels like quality compared to those china cheapies I was used to.

-Amplifier: MaxAmp20. A lot smaller than it seems from the pictures. 2x15W high efficiency class-D with digital volume control.

-Battery protection: AccuSafe V3.5. Cuts off the battery at 11.5v to prevent damage. Will auto-switch to PSU when plugged in and couple battery to the charger.

 

15913160636_9343ab409c.jpg

And last but not least: all the cables, plugs, connectors etc

 

Hope you enjoyed it, stay tuned :)

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Ahh, you beat me to it :P 

Still havn't abandoned the idea of building this setup as well.
Not sure If I'll be using it much yet, so havn't fully decided if we're gonna make it, but it'll be in the summer if and when it happens :P

Looks MUCH better than our first try at our half-assed boominator look-a-like.
COOL! :-)


Everyone have a cool signature. I don't, so I thought I would write something.

- Cool right?

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Also, that PSU looks neato.

So do you have an internal charger to charge the battery while plugged in? Or how does this work? :P


Everyone have a cool signature. I don't, so I thought I would write something.

- Cool right?

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Posted · Original PosterOP

Heyy @XzzDSA, This one will be bipole (magnet to magnet), that was the reason the bass was lacking in your build :)

Maybe you can build a Halfinator which is a fair bit cheaper and smaller. You can build it for <200 euros.

Flip it 90 degrees, make the handles/ports on the longest side, make it 1 liter larger to fit the battery etc in it.

Why not build it before it's summer so you can use it in the summer? I'll be your guide :)

 

It's bad to charge and use the battery at the same time, that's why we went with the charger/PSU setup.

When you plug it in to charge, the PSU will power the amp and the charger will charge the Battery.

It's all auto-switched by the Accusafe, so you only have to plug in the mains cable.

 

It's beginning to look like something, but the coolest thing(s) still have to come ;)

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Heyy @XzzDSA, This one will be bipole (magnet to magnet), that was the reason the bass was lacking in your build :)

Maybe you can build a Halfinator which is a fair bit cheaper and smaller. You can build it for <200 euros.

Flip it 90 degrees, make the handles/ports on the longest side, make it 1 liter larger to fit the battery etc in it.

Why not build it before it's summer so you can use it in the summer? I'll be your guide :)

 

It's bad to charge and use the battery at the same time, that's why we went with the charger/PSU setup.

When you plug it in to charge, the PSU will power the amp and the charger will charge the Battery.

It's all auto-switched by the Accusafe, so you only have to plug in the mains cable.

 

It's beginning to look like something, but the coolest thing(s) still have to come ;)

If we do decide to build it - we'll build a full blown boominator like yours.

 


Everyone have a cool signature. I don't, so I thought I would write something.

- Cool right?

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Aww mann.. This looks SOOO much better than ours did - HA!
Gj.. Might need to get a hold of some proper tools for our next attempt.


Everyone have a cool signature. I don't, so I thought I would write something.

- Cool right?

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Coming along nicely!


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Posted · Original PosterOP

@XzzDSA Thanks! Actually, it's not a whole lot of tools you need.

Required:

-Jigsaw (we got a secondhand Black&Decker for €10)

-Drill (battery powered is nice to work with) with hole saw

-Soldering iron 

-Side cutter

 

Recommended:

-Router (On my birthday, 15dec, I'll get a brand new one :))

 

@vinyldash303 Thanks, we're making nice progress indeed :)

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@XzzDSA Thanks! Actually, it's not a whole lot of tools you need.

Required:

-Jigsaw (we got a secondhand Black&Decker for €10)

-Drill (battery powered is nice to work with) with hole saw

-Soldering iron 

-Side cutter

 

Recommended:

-Router (On my birthday, 15dec, I'll get a brand new one :))

 

@vinyldash303 Thanks, we're making nice progress indeed :)

We didn't really have proper hole saw for our drill, so we used a hand-drill with a size which was aprox. the correct size.. Man, that was ALOT of work, lol.

How do you make sure to make the holes for the woofers, round? 

We just drew out the woofer on the plank and free handed it with a jigsaw. (Wasn't the prettiest thing though).


Everyone have a cool signature. I don't, so I thought I would write something.

- Cool right?

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Posted · Original PosterOP

We didn't really have proper hole saw for our drill, so we used a hand-drill with a size which was aprox. the correct size.. Man, that was ALOT of work, lol.

How do you make sure to make the holes for the woofers, round? 

We just drew out the woofer on the plank and free handed it with a jigsaw. (Wasn't the prettiest thing though).

 

You knew that there was a centerbrace, but you didn't know that there were two woofers per side?  :blink:

It took us 10-15 minutes total with the hole saw on the electric drill. The woofer  cutouts will be done using a router and a circle-jig. Perfect circles within minutes. 

 

If you don't have a router:

Draw it with a compass tool, take it easy with the jigsaw, sand off the rough edges and you have near-round circles.  

We will use this technique for the piezo cutouts.

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You knew that there was a centerbrace, but you didn't know that there were two woofers per side?  :blink:

It took us 10-15 minutes total with the hole saw on the electric drill. The woofer  cutouts will be done using a router and a circle-jig. Perfect circles within minutes. 

 

If you don't have a router:

Draw it with a compass tool, take it easy with the jigsaw, sand off the rough edges and you have near-round circles.  

We will use this technique for the piezo cutouts.

We knew that actual design of an actual boominator. We just didn't know how much all of it mattered :/

 


Everyone have a cool signature. I don't, so I thought I would write something.

- Cool right?

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Posted · Original PosterOP

*Holiday Update :D

 

I got a router for my birthday, which we used A LOT today.

Very decent product for only €65. 

 

We started the day by drawing out all shapes on the wood.

15450265244_cfc159d915_z.jpg

Just for reference, final radius will be determined by our DIY circle jig.

 

As seen here

15886802757_c084c7207f_z.jpg

Perfect circles in no-time.

 

Stacks

15885132788_f5831ba395_z.jpg

 

16070642351_7c62de23eb_z.jpg

 

Testing all woofers and tweeters. We removed the stickers on the back of the magnets so the chemical metal will adhere better.

15886481839_b09bd3e74c_z.jpg

 

Filled the groves on the piezos with sealant to reduce the plasticy resonance.

16046769756_ece5c338bb_z.jpg

 

Woofer+grill+wood

16070641431_282b6acb23_z.jpg

 

Woofer+grill+wood+ledstrip  :)

15886801837_285c603f8c_z.jpg

 

And a dry testfit to see how far we have come in a day  :D

16046769086_39957596ac_z.jpg

 

15452901873_e9d16f0587_z.jpg

 

That's was it for today. Tomorrow my friend will swing by for another day :)

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Posted · Original PosterOP

180 leds in one picture

15893812948_04fc14487c_z.jpg

 

Phone cam doesn't really do justice. You can see the woofer IRL, looks awesome.

15895161629_3bf152f26d_z.jpg

 

Mounting the speakers on the baffle using acryclic sealant.

15458948634_62ff98e63a_z.jpg

 

Letting it dry

16079329381_3cdbebbc45_z.jpg

 

So we started assembly on the AccuSafe (protection board and auto-switch between mains and battery)

16079328841_0831107c5e_z.jpg

 

Done

16081253875_51f0a9e8c3_z.jpg

 

Removed three of the five capacitors on the MaxAmp20, high pass is now on 40hz and acting as a sub sonic filter.

Looks nasty, I know. We don't have any flux to clean it up. Doesn't hurt performance in any way ofcourse.

15895491937_c10bf7da4d_z.jpg

 

Testfitting the bipole driver setup. Can you see why it's so strong when assembled? It can't flex in any way.

15893967920_d98e0f037f_z.jpg

 

Next stage: Assembly :)

 

 

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Posted · Original PosterOP
We got the terminals to the centre in place:

16263887012_a263588e56_z.jpg

 

All cables soldered and ziptied in place

15642301034_b7e7770f27_z.jpg

 

Top down view

16077190108_7f5ca5684b_z.jpg

 

We've tested it with a towel between the top and bottom and weights on top. Not exactly airtight but we can already hear how loud it can go :)

16264718845_604affbeb1_z.jpg

 

And a pic of the LED sweetness. Current consumption per strip is around 190mA at 12v according to my multimeter. So total consumption should be 760mA or 9,12W. Pretty significant, double the consumption of the amp, but most of the time they will be off or flashing on the music.

16238800606_ca7006b169_z.jpg

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Lookin sweet!


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Posted · Original PosterOP

Thanks guys!

 

No crossover needed for this build?

 

Actually, yes. Can you spot the resistor in series with the tweeters?

'Normal' tweeters are resistive and need a capacitor to create a first order RC highpass.

Our piezo tweeters are capacitive and they need a resistor to create a first order RC highpass.

 

You could use a coil on the woofer, but the midrange already has a very controlled rolloff.

Crossover frequency is around 3.5kHz.

 

There is also a highpass on the input of the amp at 40hz. It's to prevent the woofer from playing frequencies it can't properly reproduce anyway.

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