- 3.0 ft³ subwoofer box
- Dayton Audio Reference Series 15" subwoofer, 4Ω
- Paper backed flat cut cherry veneer, 2' x 8'
- Watco Danish Oil, natural
- Heavy duty rubber feet, 1-3/8" x 1"
- Speakon 2-pole panel mount connector
- #8 x 1" pan head screws
- Polyester fiberfill
- 1/4-20 x 2" socket flat head screws, black finish
As others have mentioned, the DIY Sound Group flat packs are outstanding. Mine fit together perfectly. I figured out a way to glue the panels together in a few steps using no clamps, just using a heavy box to keep the glued joints together during setup.
I'm a rookie when it comes to veneering, but the whole process was easier than I expected. I used Heat Lock glue applied with a roller to both surfaces, allowed to dry for ~30 minutes, placed them together and re-activated the glue with a clothes iron. After letting it cool I trimmed the edges using a router and a flush trim bit. There were a couple of edges I had to mash down with the iron a second time. Then I carefully sanded the edges with 180 grit sandpaper, and sanded all the surfaces with 400 grit. I flooded the veneer with Watco Danish Oil and rubbed it in on each side with 600 grit sandpaper for about ten minutes, then wiped with a cotton cloth. I love how the veneer turned out.
For the front baffle I first sprayed on a fill 'n sand primer and sanded with 220 grit paper. I probably should have sealed it with shellac first, because the first coat of black paint looked rather uneven and raised the grain (or whatever you call it on MDF). I sanded that coat with 320 grit paper and painted it again, which did the trick.
The remainder of the assembly was time consuming but simple. I drilled a 15/16" hole on the back for the Speakon mount and secured it with two #6 tapping screws. The barbed inserts for the rubber feet were secured with two part epoxy. I used about 2.5 pounds of the fiberfill in the box.
I am powering this sub with a Crown XLS 1500 amp set to bridged mono mode, which pushes 1,500 watts into 4Ω. I turned the gain pots about 3/4 of the way up and ran the Audyssey setup on my Integra pre-amp. All I can say is "wow." It subtley adds an amazing bottom end to my Epos Epoch 5 tower speakers. The sub seems to be just loafing along during music tracks but really comes alive for effects in movies. This seems to be the perfect sub for my home theater and it's great to say I built it myself.