This is really easy to do, and almost anyone with any knowledge of how to use a drill and saw can do it. Here is how:
1.) Sketch a plan of the box you want to make. Then figure out what dimensions you need to cut each panel to. Don't forget that you
will need to compensate for the thickness of the material (3/4") for edges that overlap.
2.) Go to Home Depot with your panel dimensions and purchase a 4'x8' sheet of MDF (~$10-15). Home Depot has a huge saw rack
which can cut large pieces of plywood etc. quite accurately with smooth edges. The first two cuts of your panel is free, the extra
cuts are 25 cents each. Give the Home Depot employee you panel dimensions and they will cut everything up for you.
3.) While you are at Home Depot purchase 1-3/4" drywall screws, a tube of caulking compound, and a can of 3M Super 77 spray
adhesive.
4.) Go to the back of Home Depot in the carpeting section and they will have rolls of all kinds of outdoor carpet. You can purchase the
carpet by the foot and you can get gray, black or tan carpet depending on how you want it to look.
5.) Take all of your materials home and start by labeling each panel with a pencil so you don't get confused later.
6.) Mark the position of the 12" subwoofers on the front panel and cut 11" diameter holes for the speakers.
7.) Assemble the box using the drywall screws, using a countersink bit on your drill to recess the the head of the screws below the
surface.
8.) Using the caulking compound to seal all the seams on the inside and outside of the enclosure.
9.) While waiting for everything to dry, cut the carpet into 3 pieces. Cut two pieces for the ends of the box, and one piece to cover all 4
of the faces of the box. Cut the pieces about 3-4" oversize.
10.) Spray the end pieces of the box with the spray adhesive and spray the backs of the carpet as well. Allow the adhesive to tack up,
then apply the carpet to the box, working from one edge to other making sure it lays smooth. Wait a few minutes for the adhesive
to dry, then trim the edges down to size with SHARP scissors.
11.) Spraying one face of the box at a time, stretch and roll the large piece of carpet around the large faces of the enclosure,
essentially covering those 4 sides at once. Again, let the adhesive dry a while and then trim the edges to fit. Use a slightly damp
sponge to remove any adhesive that got on the carpet and to "blend" the carpet seams together.
12.) Install the 12" subwoofers in the holes you cut in the box and drill a small hole in the side of the box for the speaker wires to come
out. Seal this hole from the inside with caulk before dropping the speakers in.
You're FINISHED! For a Saturday afternoons work and ~$40 you have a very professional looking enclosure that is much studier than store-bought glued together garbage. You can also tailor the interior airspace to match the ideal enclosure size of your subwoofers. For 2 speakers, just double the recommended internal enclosure space. I used to work at a custom stereo installation shop, and we used essentially the same process. I've built ~10 enclosures at home using this method.
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