Help me build a simple speaker box. - Finished!

Looks good to me. The thing that I don't know at this point is how I'm going to attach it to the rack. I'd like some kind of quick release mechanism so that I can remove the box for transport; maybe somehow have it slide on and lock in place somehow. It would need to be a pretty solid coupling so that the box wouldn't rattle or move around. I'm planning on hitting the hardware store to see what I can piece together, but if you have any suggestions let me know.

So it's 3:30pm (time to close up shop) and we are off tomorrow (Good Friday).

Think about this over the weekend Serengeti. If you want any changes, let me know. Otherwise I'll cut the metal (I'll be making it out of 18gage Stainless) next week and put the box together.

The clamp: you can see how big it is in relation to the box. I can go with something smaller if you want but please remember: this is virtually a free box. I'd like to work with the hardware I have on hand here.

Oh yeah: take pictures of the back of your bike with no panniers attached so I can see what you're working with. Maybe I can come up with some kind of quick release system for fastening the box to the back of the bike.

FSeven wrote:

So it's 3:30pm (time to close up shop) and we are off tomorrow (Good Friday).

Think about this over the weekend Serengeti. If you want any changes, let me know. Otherwise I'll cut the metal (I'll be making it out of 18gage Stainless) next week and put the box together.

The clamp: you can see how big it is in relation to the box. I can go with something smaller if you want but please remember: this is virtually a free box. I'd like to work with the hardware I have on hand here. :)

Go with what you've got man, and feel free to bill me appropriately. It's looking great!

Maybe you guys should make these and sell them. Serengeti certainly isn't the only biker who would want one. I would bet you can sell a bunch at RAGBRAI.

That's not a bad idea. FSeven, if you wanted to put your website address or phone number on it as a bit of advertising, that'd be totally cool with me!

My concern with developing this for a broader market is in regards to exactly what we are facing now: trying to figure out a way to mount this on your bike.

FSeven wrote:

My concern with developing this for a broader market is in regards to exactly what we are facing now: trying to figure out a way to mount this on your bike.

With so many different racks out there, it would be pretty much impossible to build anything universal. Anyway, don't worry about the mounting mechanism for mine; I'm pretty handy and I'll figure something out!

Either way, if we were to come up with something it would have to be a device welded onto the box. So at least I can get started on the box itself.

Before I start cutting, is there anything you want laser etched onto it? Like maybe a fancy S for Serengeti, a picture of Stan from GWJ, etc.?

FSeven wrote:

Either way, if we were to come up with something it would have to be a device welded onto the box. So at least I can get started on the box itself.

Before I start cutting, is there anything you want laser etched onto it? Like maybe a fancy S for Serengeti, a picture of Stan from GWJ, etc.?

Hmm, can't really think of anything. Over time I imagine the box is going to be covered with team stickers for decoration

I was thinking about coupling the box to the rack and I came up with something like this:

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/couple_zps1f492d40.png)

It's basically two 3"x8" (or so) pieces of steel bent so that they would slide together lengthwise in a rail-like fashion. The bottom piece would be permanently affixed to the rack (I can find someone to weld it on) and the top piece welded to the box. There would be a stopper on one of the pieces to prevent any further forward sliding once the two pieces are connected and then maybe a latch similar to this to prevent it from sliding back out.

IMAGE(http://m2.sourcingmap.com/smapimg/en/n/11d/hardware-case-boxes-spring-loaded-metal-toggle-latch-catches-173798n.jpg)

What do you think?

Serengeti wrote:

I was thinking about coupling the box to the rack and I came up with something like this:

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/couple_zps1f492d40.png)

It's basically two 3"x8" (or so) pieces of steel bent so that they would slide together lengthwise in a rail-like fashion. The bottom piece would be permanently affixed to the rack (I can find someone to weld it on) and the top piece welded to the box. There would be a stopper on one of the pieces to prevent any further forward sliding once the two pieces are connected and then maybe a latch similar to this to prevent it from sliding back out.

IMAGE(http://m2.sourcingmap.com/smapimg/en/n/11d/hardware-case-boxes-spring-loaded-metal-toggle-latch-catches-173798n.jpg)

What do you think?

I think you're on the right track. My only worry with this would be the amount of vibration from riding as well as from the speakers. If the box is fastened in any way less than very tightly, there will be so much jostling around and vibration of the metal I think it will be detrimental to the whole idea.

I also want to stay away from drilling any kind of holes in the box for water proofiness purposes. Unfortunately, that would be the best way to secure the box to your rack.

What is the diameter of the tubing used on that rack? Also, those two bolts sticking up from that rectangular plate on the front of the rack (nearest the seat). What are those for? Do they need to be there?

The tubing is 3/8" diameter. Those bolts anchor the rack to the tubing connected to the seat stays, so they're required.

FSeven wrote:

Oh yeah: take pictures of the back of your bike with no panniers attached so I can see what you're working with. Maybe I can come up with some kind of quick release system for fastening the box to the back of the bike.

The rack tubing is 3/8" diameter. My first though its some kind of latch that clamps onto the tubing directly. Here are some pics:

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/null_zpsc7dda887.jpg)

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/null_zpsb2ba2779.jpg)

The box has arrived! Major thanks to FSeven for putting this together for me, it's awesome! Here are some pics of putting it all together.

Components removed from the old bag and laid out, ready to go. The 6.5" speakers are from the old box, the 6x9s are for the new one. I'll have to figure out something to use the old speakers for...

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zpse59a414c.jpg)

Battery compartment is a perfect fit! No movement of the battery at all, which is important; you don't want it bouncing around.

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps1bfd9b1a.jpg)

Testing the speaker fit. Yup, holes are the right size

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zpsf55eed4b.jpg)

First speaker attached.

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps9c7969f2.jpg)

Both speakers bolted in place.

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zpsd34ab3f0.jpg) IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps25f5f97b.jpg)

Amp in place and wired.

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps2ec57d5d.jpg)

All put together and running!

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zpsf56537c3.jpg) IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zpsaaf9ce2e.jpg)

Still working on the mounting system; I'll post photos of that later today!

And done! I wanted to go with a quick release mounting system, but I couldn't come up with anything that would work and not have the box rattling on the rack. I ended up with a pair of hooks on the front covered in plastic tubing and a u-bolt on the rear. It's very tight and doesn't allow for any movement between the box and the rack. To take the box off there are two nuts inside that need to be removed from the u-bolt, so while it's not "quick", it's not too difficult either.

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps80ada59e.jpg) IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps7475a73f.jpg)

Finally the whole unit mounted on the bike.

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps36964d4e.jpg) IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/Bike%20Stereo/th_null_zps4eef8d24.jpg)

Again, thanks FSeven for the awesome box! Gonna take her downtown this evening on her trial run, then a 90 mile ride tomorrow!

Nice. It looks great!

This is crazy cool.

Rode 140 miles over the weekend, rocking it the whole way. Love the new stereo!

Awesome! Glad to see everything fits as intended. I'm a little upset about the speaker mounting holes. I could have sworn my dimensions based on the schematic were correct. In the meantime you can probably fill it in with silicone or something or even take it to a metal shop and pay a welder a few bucks on his lunchbreak to fill in the holes real quick. Then a quick rubbing with ScotchBrite and you'll never know holes were there at all.

Rode 140 miles? Forget the box. How about some pictures of your calves?

Glad you're happy with the box.

Couple of action shots from the weekend!

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/null_zpsd6caabf3.jpg)

IMAGE(http://i135.photobucket.com/albums/q133/serengeti000/null_zps25dc00b9.jpg)

FSeven wrote:

Awesome! Glad to see everything fits as intended. I'm a little upset about the speaker mounting holes. I could have sworn my dimensions based on the schematic were correct. In the meantime you can probably fill it in with silicone or something or even take it to a metal shop and pay a welder a few bucks on his lunchbreak to fill in the holes real quick. Then a quick rubbing with ScotchBrite and you'll never know holes were there at all.

Actually I think I'm gonna stick some LED lights in them; it'd look pretty cool at night

Fantastic pics! Looks like you have a nice little group there that loves to ride. And loves plaid.

What kind of tunes do you crank through that bad boy while riding?

LED's for night riding would be awesome. Would it be hard to program the LED's to "dance" in sync with the music?

FSeven wrote:

What kind of tunes do you crank through that bad boy while riding?

I like to switch it up as we go. Saturday morning was kind of a classic rock ride, but by the early evening we were well into club/dance mode

FSeven wrote:

LED's for night riding would be awesome. Would it be hard to program the LED's to "dance" in sync with the music?

It doesn't seem like it would be difficult at all, but I'd have to look into it.

Finally got around to weighing the stereo; came out at 20 lbs even. Not too bad!