DIY Speaker - Amazon Web Services...Stretch the hole over the rubber tube & paper cylinder you made...

DIY SpeakerMake your own speaker!

Written By: Kailash NR

DIY Speaker Release: 2.0 [major] 2019-06-28Guide ID: 367 -

This document was generated on 2019-09-17 02:33:15 PM (MST).

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INTRODUCTION

Using paper cups/aluminium can, some insulated wire and a magnet, create a wonderful speakerthat produces sound!

TOOLS:Scissors (1)Glue (1)Coin (1)Insulation Tape (1)Audio source (1)

Mobile/CD player/MP3player/Transistor/ComputerAny device with an audio port

PARTS:Aluminium can (1)Neodymium magnet (1)

10x10Paper (1)

100 GSMLength 29.5 cm, Width 5 cm

Butter Paper (1)Enamelled copper wire (1)

35 gauge10 m

Connecting Wire (2)15 cm

Audio jack (1)30-50cm

Rubber pipe piece (1)6 mm diameterLength - 5 cm



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— Precautions

Scissors have functional sharp edges. Contact may result in injury. Always keep blades away fromfingers and body. Handle with care.

Be careful while handling metal pieces, they may cut the skin if handled improperly.

— Step 1 - Cutting the Can

Using scissors, cut an aluminium can to a 3.5 cm height from its bottom.

Put a drop of glue in the centre of the bottom dome on the inside.



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— Step 2 - Gluing the Magnet

Now flip the can around and place a coin on the bottom from outside.

Hold the coin to the can with your finger and turn the can while still holding the coin in place.

Now lower the neodymium magnet onto the blob of glue you put in the centre. The magnet shouldnow be held firmly to the bottom of the can because of its attraction to the coin on the other side.

— Step 3 - Cylindrical Base

Take a 5 cm rubber pipe and wrap it completely with a 5 cm wide strip of paper, whose length isthe same as that of an A4 sheet (i.e. ~30cm).

The paper strip should taken from a 100 GSM A4 sheet.

When the complete paper strip is rolled over the pipe, secure it with a piece of tape, to prevent itfrom unravelling.



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— Step 4 - Paper Cylinder for Coil

Take a piece of paper of dimensions 5 cm x 5 cm and wrap it around the base cylinder, which wasmade in the previous step.

— Step 5 - Applying Glue

Wrap the paper strip completely and glue it at the edge.

Be careful not to glue the small paper strip onto the base cylinder while putting the glue.

From any one end of the paper cylinder, make a mark at 7 mm.



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— Step 6 - Marking the Paper Cylinder

Draw a line along the circumference of the cylinder at the 7-mm mark.

At a distance of 5 mm further in from the previous line, draw another line along the circumference

— Step 7 - Winding the Copper Wire

Leave about 5 cm of copper wire free from one end, and start winding the rest around the papercylinder.

Restrict the width of the winding between the two markings made in the previous step.

After the first layer of winding, apply some glue to it so that it forms a stable base to wind morelayers on top of it.



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— Step 8 - Winding Complete

As you finish winding the wire, having made hundreds of turns around the cylinder, leave about 5cm of wire free at the finishing end as well. The two free ends will be used for making electricalconnections.

Apply some glue on top of the last layer of the winding to prevent the winding layers from slidingoff.

While winding the wire, periodically put a layer of glue after each layer of winding such that thecopper loop stays tight, neat and does not unravel.

Twist the free ends together a few times, as close as possible to the winding,

— Step 9 - Scraping the Copper Wire

Scrape off the insulation from the free ends of the copper wire using a cutter, scissor blade orpiece of sand paper.



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— Step 10 - Connecting the Wires

Take two connecting wires. Remove the insulation from both the ends of each of the wires.

Connect the scraped ends of each of the copper wires to one end of each connecting wire.

— Step 11 - Securing the Connections

Secure the joint of copper wires and connecting wires using insulation tape. This is also done toprevent the bare joints from making contact with each other.



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— Step 12 - Securing the Terminals I

Make a knot on both the connecting wires close to the joint where the tape has been put in theprevious step.

While tightening the knot make sure there is a little space between the tape joint and the final knot.

— Step 13 - Taking out the Coil

Carefully pull the outer paper cylinder off from the base cylinder. You should get a hollow cylinderwith the coil wound around it.



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— Step 14 - Terminal Holes

Using scissors, make two small holes, 1cm up from the bottom of the aluminium can.

The gap between the holes should also be about 1cm.

— Step 15 - Securing the Terminals II

Now take the end of the insulated wire and push it through the hole in the can from the inside tothe outside.

When the wire is pulled, the knot should get caught at the hole; this helps relieve the stress on theconnection joint.



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— Step 16 - Inserting the Wires into the Can

Repeat the process with the other wire and the other hole.

Now glue the wires to the inside of the can and leave them to dry.

Mount the paper tube on the magnet with the coil-side at the bottom; i.e. the coil should effectivelybe surrounding the neodymium magnet with just the thin piece of paper in between

— Step 17 - Trimming the Voice Coil

At this point the coil assembly should look like the first image shown here.

Cut the paper tube such that it is a maximum of 1cm taller than the cut can.



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— Step 18 - Preparing the Diaphragm

Start with a rectangle piece of butter paper, about 10 cm x 10 cm, and fold it in half.

Now fold it again along the other axis.

Using scissors, cut off the corner where all four sheets are folded. (This corner corresponds to thecentre when the sheet is opened.)

— Step 19 - Mounting the Diaphragm I

When you open the sheet (your diaphragm), you should have a diamond-shaped hole in thecentre.

Stretch the hole over the rubber tube & paper cylinder you made in Step 3.

Now place the base cylinder and diaphragm slightly into the paper tube (which is inside the can).



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— Step 20 - Mounting the Diaphragm II

Now gently push the diaphragm from the base of the cylinder onto the paper tube.

Push the diaphragm a little more than 1cm down the paper tube. This will make sure that the coilisn't resting on the bottom of the can, but is instead suspended from the diaphragm.

— Step 21 - Gluing the Diaphragm I

Glue the paper tube to the diaphragm, taking care that the glue doesn't leak into the can.

Flip the can with the diaphragm still in place.



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— Step 22 - Gluing the Diaphragm II

Now glue the diaphragm to the rim of the can. Make sure that you apply glue throughout the rim ofthe can and where it makes contact with the diaphragm.

Ensure the paper tube is aligned above the magnet, with a small uniform gap between the magnetand tube.

When the glue begins to set, cut off the excess parts of the diaphragm. Leave a little extra of thediaphragm around the rim of the can. Fold this extra section down onto the can body and glue it tomake the seal more robust.



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— Step 23 - Attaching an Audio Cable

Strip the insulation off the open end of the audio cable to expose the three insulated wires inside.These wires are colour coded: red or pink for the left channel and white/grey for ground.

Connect the wire of the completed speaker to the left and ground wires respectively.

Tape the wire joints with insulation tape. Make sure the joints don't touch each other when you aretaping them.

— Play!

Once the cable has been securely attached, the speaker is complete.

To ensure the best sound quality and loudness, ensure that the gap between the magnet and coilis maintained.

Plug the jack into a music source, such as a phone, mp3 player or computer, turn on the musicand listen with your ear against the bottom of the can!



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— Troubleshooting

If the speaker doesn't produce sound, this could be because of a loose connection in theconnecting wire or a break in the coil.

If the sound produced is low in volume, adjust the diaphragm position and tension till the volumeincreases.

To ensure the best sound quality and loudness, ensure that the gap between the magnet and coilis maintained and the coil is right above the pole of the magnet.



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DIY Speaker - Amazon Web Services...Stretch the hole over the rubber tube & paper cylinder you made...

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