DIY speaker using high quality JBL speaker

Hi,

I cant afford buying a device like JBL BOOMBOX (it's a bluetooth speaker) but I found the speaker (the one that provides strong bass) and tweeter very cheap online (I paid 20 dolars) of this exactly same device (JBL BOOMBOX - it has 2 speakers and 2 tweeters). Picture below of the JBL BOOMBOX and of the speaker I bought:

aaa.png
bbb.png


The speaker is 4 inch, 4 Ohms and 30W RMS. It arrived today (it's original), so I connected it to my amplifier (which can drive much bigger speakers) but the sound does not look loud, it is actually very low (I even used a 10uF capacitor to filter mid/highs but the sound is not strong). I know I should put this speaker inside some type of wood box to make sound better and louder but I have no idea which size the box should be, if it should be sealed or if I should make a hole to allow air to to in and out. I know the JBL has radiators but despite being all plastic, they are very expensive (I have no idea why). There are plenty of speaker (like home theater speakers) that dont use radiators and have strong bass and loud sound.

So any idea the dimensions of the box that I should try? And what about the capacitor? Do you think 10uF is too much? The tweeter still didnt arrive, but for now I would like to try making the speaker sound better.

I know the JBL BOOMBOX has 2 speakers and 2 tweeters, but I still think the sound is very low... any idea how I can improve this? Do you really think using a wood box would help a lot?
 
Last edited:
You can start collecting speaker specifications by dimensional measurement, and a multimeter, then use ROOM EQ WIZARD to get more info. Might be enough to allow you to determine an appropriate enclosure. The original design uses a passive radiator for sure.
BUT!!!! I don't understand your post. your goal is to make a portable speaker? if so, you started out in the worst possible way IMO. If you have any not very valuable speakers INSIDE enclosures laying around (like the three way speakers that come with those CD/TAPE/RADIO stereo sets) Go to amazon and get a bluetooth amp board for 14 bucks, then (again, with the batteries you have laying around) nail the amp to the speaker and affic the batteries. I actually made a pretty boss BT speaker with a little set of 3 way wedges I got a few years ago for twenty bucks.
Alternatively, Get yourself a bluetooth speaker man... just not the JBL. between $20 and $50 there are a TON of BT speakers. Even ones for thirty, forty bucks that don't seem half bad- batteries, carry strap, amazing wattage claims (which when adjusted down are still not terrible). maybe you can return that speaker.

or you can take the speaker measurements, construct a very VERY close tolerance sealed enclosure with a passive radiator, use a capacitor as a high pass filter for the tweeter, etc.
But that is a very, very AMBITIOUS idea. Like trying to live in a sand castle.
 
Please supply a link to the online source of this 4 inch driver. Hopefully, it will include the driver's specifications.

You should be aware that the JBL Boombox uses electronic sound processing to produce loud bass. An ordinary amplifier does not include such processing.

Of course the 4" driver will need a box. Without a box the low frequencies from the rear of the driver cone come round and cancel out the low frequencies from the front of the driver cone - the result is no bass. You can try a sealed wooden box of internal volume 8 to 10 litres as an experiment. Best to first mock the box up in stout cardboard to see how the bass sounds before actually building a wooden box.

Regarding the tweeter capacitor, I would suggest 4.7 uF for a 4 ohm tweeter or 2.2 uF for an 8 ohm tweeter. Place the cap in series with the tweeter.
 
  • Like
Reactions: JMFahey
You sure it´s the exact same speaker JBL uses?
Where did you get it from? Please post a direct link.

Testing it without a cabinet is meaningless, mount it at least in a shoebox sized box.

Or get a bucket, say 8 to 10 liters, put a piece of wood covering its mouth, maybe even 2 sheets of cardboard glued together , cut a speaker sized hole and mount it there.

Not sure what you did with the 10uF capacitor, I fear you shorted the amp with it.
 
  • Like
Reactions: Galu
@mindgames11 I already bought bluetooth speakers, and all the cheap ones are terrible. Regarding the amplifier, I intend to use the Pam8610 with this speaker, making it very portable, cheap and easy to use/configure. I already connected the pam8610 with this speaker and it works fine, however the sound is not loud.

@Galu I bought the speaker directly from a reseller here in Brazil. It's 100% legit, came with receipt from JBL as he is a distributor. So the speaker is not the problem. Regarding the box, do you think making a try with a cardbox should improve the sound? I know I will use wood later, but are you really sure using a cardboard I will be able to listen a difference in sound quality? I will follow your suggestion of 10 liters (squared box). Do you think I should use a hole to let the sound out or I should seal it?

@JMFahey I will do what you said, same as @Galu told me. And I will be back here to tell you the result. The capacitor I used in series (not in parallel) so it removes the high frequencies. Isnt this a good practice?

Summary: guys, if I can veeeery cheaply buy an original JBL speaker, and if I can very cheaply buy a mini amplifier (which i already tested with the speaker and it worked great, no overheat, no issues)... why should I try buying cheap bluetooth speakers? I already have 2 and they are not good, not loud, not enough bass... and battery sucks. Doing my own portable speaker, I can use good quality 18650 battery cells and do a great job! But I really dont understand the physics regarding the wood box size, if I should leave a small hole for the air or if it should be sealed...
 
@ batata

Don't use a capacitor with the 4" driver. You would need an inductor (coil) to prevent high frequencies reaching a mid/bass driver, but this is probably not necessary in your case.

You must use a capacitor in line (in series) with the tweeter to prevent the low frequencies reaching the tweeter.
 
  • Like
Reactions: JMFahey
@Galu thank you so much my friend. I will do exactly what you said (the tweeter still didnt arrive but I will use it with the tweeter). Regarding the box using cardboard, do you think I must make a small hole to let the air leave the box? Or just the hole to fit the speaker?
 
Do you think I should use a hole to let the sound out or I should seal it?

Seal the enclosure. We have no idea what size of "hole" or port we might use - such things have to be calculated knowing the specifications of the driver. Best to try sealed first and then let us know how you got on. A temporary enclosure (JMF's bucket suggestion is great!) is good enough to tell how good the bass might be in a wooden box.
 
Oi Irmão, tudo bem? 😉

It´s not important, it´s just a test, just leave it "sealed" (with lots of leaks around 😉 )

Please show a direct link to that woofer anyway, we want to know which one it is and see its parameters.

"It´s a JBL" (actually a Selenium) tells us nothing useful.

EDIT: as of cloning that JBL boombox:
I bet you will get a good result, I suggest you get as high a voltage battery as possible to feed that PAM8610 amp,
With 12V supply you can get 10W into 8 ohm and 15W into 4 ohm, but this one requires a heatsink, not sure your amp has one.

1) as you see, we need that speaker datasheet, so a direct link.
A direct link to your amp would also help.

2) consider that JBL has lots of resources, which they must have applied to their design, so at least I expect:

* they measured that speaker and designed the best possible cabinet for it ... we may approach that.

* plastic is despised but in fact is the Technologically advanced solution, they may easily create shapes, vents, geometry, we can only approximate by cutting and gluing wood panels.

* they certainly apply as much DSP processing as needed to optimize sound in such a small enclosure, mainly equalizing, limiting (so as to play loud but not distort), even create synthetic Bass,such as:
https://ask.audio/articles/review-pump-bass-maxxbass-waves/es
 
Last edited:
@JMFahey opa brazuca!!! Thank you for your message, I will read it carefully in a few minutes, first I would like to show you the video I made!

I appreciate all your kindness people, helping me with this speaker. I made a video following your instructions, the link is below:

https://photos.app.goo.gl/pf86a5XF2pufUqJF8

Of course I dont want to build a JBL BOOMBOX clone with 100% the audio quality, if I can get 50% I will be more than happy! But watching the video above, would you suggest any other improvement I shoudl do in the cardboard box? I will be glad to try everything you suggest and record a video so you can check if i am doing right!
 
@JMFahey now I got time to read what you said! Looking at the JBL BOOMBOX product, I see the battery that comes with it is a 7.4V one (2S). I am already using a 12V power supply, and I think if I go over this I might damage the speaker since the JBL product is rated to 7.4V and I doubt it has an internal voltage boost... I just cant understand how this JBL speaker can reach 30W since with 7.4V battery the current would have to be almost 4A, that's too much... but JBL rates it at 30W.

I will be glad if you guys could take a look at the video I made and check if I could improve something. Anyway, I already appreciate all the kindness you provided me!
 
All JBL speakers use a step-up to boost the operating voltage above the battery voltage. Most Run TPA amplifier chips and a custom DSP and controller to equalise the response. Simply connecting a speaker to an amplifier will not work. You will need some sort of filtering to flatten the response, specially adding baffle step. Some simply BSC circuits are available on Rod Eliot's site, along with the theory of why they are needed. Try to se a passive filter, those end up saving some amplifier power.

Cardboard is very leaky, and while it forms the shape, it is acoustically undesirable. I've built in clay pots and plastic boxes when I started 35 years ago, and while thoseare quite resonant and messy in their own right they aren't as leaky as cardboard.
 
@ batata

Regarding the 30 W speaker rating - that is the maximum rating.

In actual use, the speaker will be consuming only a fraction of that power.

So, on average, the current from the battery will be much smaller than you may think.

P.S. I talk about your project which won't employ a voltage boost like JBL does.
 
Last edited:
It's much cheaper to DIY speakers......... when someone else does the design 😀

The boombox has 2 passive radiators on the side.

I'd suggest getting :

  • one 100mm female-female "extender" PVC pipe fitting
  • one 100mm male to 32mm female fitting to plug one side
  • one 100mm male to "the size of your driver" female fitting to plug the other side and put the driver in
  • a little bit of 32mm pipe
  • duct tape

By sliding the two ends inside the female-female fitting you can change the volume of the enclosure. Then you can make a port with the 32mm pipe.
 
You are going in the right direction and of course this is just a test to begin with.
So far you are doing good.

WHEN 😉 you post a speaker direct link, hopefully we´ll get its datasheet with NEEDED data, at least resonance, but full Thiele Small parameters much better. THEN somebody may help you design an optimized cabinet, suggest tuning, etc.

There are cabinet design tools available here in this Forum with full threads dedicated to that.

If too much of a "learning curve" for "just one" , then the experimental approach suggested above is next best.

Without extra parameters known, you may try either a shoe box sized wooden box or for maximum portability minimum weight a section of PVC pipe which , believe it or not, is a respected way to build cabinets, with good results.
https://www.diyaudio.com/community/threads/pvc-pipe-speakers.272360/

In both cases the main point is getting light but rigid cabinet walls.

Don´t worry too much about speaker position or "adding a hole", those are factors too but first solve the main problem.

12V supply is fine, PAM doesn´t stand much more anyway, and you avoid a step up converter which as also suggested above, is most certainly used by JBL.

So in a nutshell: build a box/tube of a convenient size, mount the speaker , you will also need to cut a hole somewhere for the tweeter, think on how to mount amp, battery, plus necessary power and audio jacks, maybe a volume control, a power switch and a Led ... and you are done.

It being a boombox: a carrying handle, maybe a strap to hang from your shoulder, rubber legs so it doesn´t roll, etc.

AFTER it´s built and working, you can tweak the design, but go step by step.

PS: no need to go that far, but for the Nobel Prize of PVC pipe Boomboxes 😱


Famous Fender Amp Can.
Speaker is 6" so you can estimate length (12"?) from that, scale it to your own speaker:

amp can.jpg
 
Last edited:
First of all, you guys are AWESOME!!! You gave me great ideas, the pipe one (that @peufeu and @JMFahey suggested) is the easiest solution to me!!!! You guys are so smart and creative!!!! I will do exactly that and will post you results!

So far, I tried mounting the speaker in a small food plastic container (instead of the cardboard I tried previously) and I can say that the bass was even better! Maybe because it has a better seal or is more rigid... it just shows how awesome will be using pipe!!! But using the food plastic container got me thinking: many of you suggest a 10L cardboard box. Why 10L? The total volume of the JBL BOOMBOX is probably no more than 2 L! It's 80% less than you suggested. So, now that I will try the pipe method, what volume you suggest me to start?

Also, if I take a pipe and fit the speaker on one side and in the other side I fit the tweeter (I dont intend to have 2 speakers, at least for now) and make it very well sealed... do you think I would have a good result instead of inserting the speaker on one side, a radiator in the other and a twetter in the middle (perpendicular to the speaker-radiator axis)? I am really thinking if a radiator would help... it's not cheap, is costs more than the speaker... or I can do a "homemade" version of a radiator? Maybe fitting a very strong/thick plastic to one side of the pipe, closing it and in the other end the speaker? I couldnt find any cheap radiator, maybe using 2 speaker on each end of the pipe will be cheaper... I am just afraid that using 2 speaker at the same time they might fight with each other increasing the presure inside the tube when both move in the tube... the radiator would move out when the speaker moves in to compensate... but using 2 speakers I think could cause problems, right?

And one final question about the pipe: some people insert foam inside the pipe, others leave the pipe empty (with just air)... which would be better?


11.jpg



@peufeu I really really liked your idea!! When you say a pipe, you mean a literal pipe, right? Like those used to flow water inside, right? So what you are saying, is that I should take a 100mm diameter pipe an fit on each side a speaker? Thank would create a very nice sealed "box"! But I didnt understand when you started talking about female and male... I tried googling but didnt understand what you said. Would you mind just posting a picture to me? Also, do you really think those radiators do any good? I always thought they were there just for the "looks", to look cool. Maybe I could use a pipe and in one end put the speaker and at the other end the radiator? Then I could drill a hole in the middle and add the tweeter? Was this what you were saying my friend?


@JMFahey I dont know if I can post links in this forum, I will try! Here is the link where I bought the speaker:

https://produto.mercadolivre.com.br...xa-som-jbl-boombox-original-c-nfe-30w-rms-_JM

It has almost no information... it just says is a replacement for the JBL BOOMBOX speaker 🙁

The link to the other thread with pipe, is very very informative!!! So I could just stick the speaker to one side and the twetter to the other? Or maybe a radiator do the other? Do you think radiators are any good?

Also thank you for the youtube video, it's gold!!!! I will inspire on it to make my boombox! Hopefully my next post I will bring you pictures!


@Sangram Thank you for your response. In my particular case I dont think increasing the voltage will help because with only 12V I already see the speaker making very strong movements... maybe with more voltage I could damage it.
 
Last edited:
We are trying to find technical data about your speakers.
Mercado Livre ad shows 4 pictures but none from the back, is there any label there?
Even if an inked one applied with a rubber stamp, or any little sticker.
Did speakers arrive in a cardboard box? ANY labels on it?

Meaning: I am certain they were made by Selenium "JBL" so I want to find the datasheet in the Selenium/JBL site.

Unless these ones are Chinese made that is.

If no data available you will have to fully measure them yourself .... or plain mount them in a piece of pipe and call it a day.

We don´t even know speaker diameter or impedance 😱 so at least answer that.

As of size: if no Math possible, Plan B is: get a piece of PVC pipe same diameter and length as original JBL boombox , mount speaker at one end,

EDIT: I found info on a similar JBL speaker, this is the strong EQ applied by DSP to achieve "impossible" Bass:

2330261544647139689.png



Measured frequency response achieved with/without DSP equalization ..... which is incredibly good given size and portability:

9384611542302102307.png


My point?: build a "normal" (pipe)speaker cabinet, mount speaker, etc. , it will work.
No wall shaking Bass of course.

THEN if you wish you may apply some EQ to improve it.

EDIT 2: IF passive radiator costs more than a speaker, personally I would add another real speaker atbthe other end, together with its own PAM amplifier .

You will have twice the power,stronger sound, including Bass, but of course twice the battery drain.

Your choice. 🙂
 
Last edited:
Thanks, I read too fast and missed that.

So it´s a nominal 4" speaker.
Since it´s a square frame with rounded cormers, you must measure that and get a same diameter PVC pipe, ypu´ll have to seal somehow the square/circle difference, as easy as cutting a proper shape "ring" out of Masonite , plastic ,or thin plywood.
Glue adapter ring to PVC tube, using something like Silastic silicone sealer, then you can screw speaker to it.

Make the tube, say, 30 to 50 cm long, get an end cap for the other end at the hardware store which will fit perfectly and then cut holes, mount stuff inside, etc.

You can make it in 1 day.

On second thought, get another end cap for the speaker end, and cut a speaker mounting hole on it.
Also try to find some speaker grill, metal or plastic, to protect it.

In fact, I got the itch and might build a tubular boombox for myself, go figure 😉

Let´s see what random speakers I have lying around, I make my own speakers but can´t make "just one", minimum batch of anything is 100 🙁

Although you gave me an idea, I might commercially make 100 (or 50 using 2 speakers each) battery powered Guitar or mini-PA speakers.

Going through Winter now but I guess in next Spring they will sell like hot cakes.