2004 (3rd gen) Dodge Ram REGULAR CAB.
This will be a How-To for 2 simple sealed enclosures for 12 subwoofers in a regular cab 3rd gen Dodge Ram.
First and foremost, I am using 2 Diamond Audio D3 12 subwoofers.
The recommended air space from Diamond Audio for a single sealed enclosure is 1.5 cubic ft, these enclosures will be 1.19 cf which is a little smaller but wont damage the drivers (woofers). I have designed the boxes to fit snugly behind the seats and still have room between them for the amp and a tray.
Dimensions for each enclosure are the same:
Top depth: 6
Bottom depth: 11:
**Keep in mind to account for the 5/8 when measuring cuts**
I am using 5/8 MDF(medium density fiberboard), $17 from Home Depot.
Tools and supplies:
Circular Saw with fine tooth blade
Dremel with Router attachment
1 framing nails
The order of the pieces will determine what measurements to make. I will start by cutting the back piece in full W and H (15X22.5)
Next, I will have the two side pieces fit into the back and front, the top and bottom will fit inside the two sides, front and back.
Cut the two sides next. Since they will fit inside of the front and back you need to subtract 5/8 from both the top and bottom depths. 5/8=.625, multiplied by 2=1.25
Height will not be affected so stick with 22.5
Once you have the sides cut, you will need to make sure the front of the top piece has the correct angle to make it flush with the sides.
Measurements for the top piece will have 5/8(.625) subtracted from ALL sides.
And the front must be cut at the angle specified before. This is what it will look like if cut correctly.
The same goes for the bottom piece, .625 from all sides.
Look familiar, these are the same measurements of depth for the two side pieces.
The front pieces gets cut last, and use the length of the two side pieces as your guide since the angle will make the length longer than 22.5. When all fitted together it ended up being 23.25.
Here are all of the pieces
I highly recommend assembling the pieces before securing with glue and nails to assure you dont need to recut any piece.
GLUE AND NAILS
I am using wood glue, however ran into a problem with a poor cut so will be using extra wood glue to fill the gap.
Apply a continuous line of wood glue to the piece to be attached.
Assemble the two pieces and secure with the framing nails
I spaced the nails out about 2 apart.
Just for safe measure I verified the two pieces with a 90degree ruler.
Alright now the same method applies to the other side piece and the top and bottom pieces.
I pushed in excess glue into areas that didnt fit up real tight, be sure to wipe away any excess after this.
The semi-completed boxes
CUTTING THE SUB HOLES
This portion is quite important to assure that the sealed enclosures stay sealed.
The Diamond webpage states that the diameter of the cut should be 11.1. I am going to measure 11 to compensate for imperfections.
I have decided to make the sub 3 from the bottom of the box. I will show you the first hole completed to help explain the pics for the second cut and how to measure it.
Measure 3 from the bottom of the board and make a mark.
The center of the hole will be the center of the entire width of the board. The width is 15 so make a mark at 7.5
Now from the 3 mark measure up 11 towards the top of the board. This will be a guide for the circle line.
In order to meet up the center of the height with the 7.5 width mark divide 11 in half and meet the 5.5 up with the 7.5
Now you will need the compass. Spread it out to 5.5 and place it in the center that you previously measured.
This is the template you will use to cut.
I am going to free hand the dremel so I have drilled guide holes around the circle to help speed up the router. I had to make 3 separate cuts each at Ό depth at a time to complete the cut.
Without using commercial tools, your hole may not be perfect, however a little sanding will smooth out any rough spots and the seal will still be good.
To seal your enclosure, apply a bead of wood blue liberally to all seams. Although some say its ok to use, I typically stay away from silicone caulk and liquid nails to prevent any deterioration of the subwoofer.
Now you will need to cut the holes for the speaker terminals. I have placed them on opposing sides of the two boxes. This will allow both terminals to face inward when put in the cab.
I have opted for terminals that will accept banana posts. I dont have pics currently of the banana posts but will post some as my project nears completion.
Measure the inside of the terminal and measure out a diagram on the box. I drilled holes in each of the corners to allow the jigsaw blade in to cut.
While the glued seams are drying, I chose to countersink the finishing nails so I can apply wood filler. This will allow you to sand the box and there should be no sign of any nails or screws.