Custom box made from aluminum?

[trippy1313]

What so you guys think? I just had a goofy thought of attempting a custom box made of maybe like 1/8" or thinner aluminum. Crazy idea but I was thinking to do something, just don't know what. Based on what I quickly looked up, just the case before cutting out speaker holes, would likely weigh about 12 pounds (@ 1/8" thick material 25"×14"×4"). But I haven't looked up what all the additionals would weigh, (speakers, tuner, amp, etc.)

I probably won't go through with anything but thought that'd be fun. I can aluminum Mig weld even thinner sheet aluminum. I figured welding the front, too, bottoms and sides, then finding a way to attach the back. Would the aluminum mess with how well a tuner or bluetooth module works?
Tell me if I'm nuts or if you have better ideas.

 

[jimmyjimmy19702010]

I think the aluminium case would act as a shield that would effectively block the incoming BT signal.

An aluminium case would also provide plenty of reasonance when it has to contend with vibrating speakers.

 

[floyd]

It would be interesting to see. Rock on.

If I could weld aluminum I'd make all kinds of s***
.

 

[BassHead]

I once inspected a large (120ft diameter) stainless steel tank (1/4" thick). It had a 36" manhole that was open at the very top. I was there all day, and was able to get phone calls. Maybe the speaker grills would provide enough space to allow BT

But I also not sure how the properties between SS and Aluminum would differ? Aluminum is more pliable and lighter of course.

 

[JustCruisin]

Crazy ideas sometimes work.. keep at it!

 

[trippy1313]

Hmm. I know the worst part of just making one would be cutting it, since I don't have any milling type equipment. We've got a plasma cutter but still... blades and grinding discs tend to get clogged with aluminum.

 

[caution]

If you draw something up, there is a place by me that will laser cut from anything they have in stock, even your own stock but it won't change the price.
They bend too.

 

[floyd]

You can also cut aluminum on a table saw and with a miter box but you have to use an 80 tooth carbide tipped blade and go nice and slow don't push it through too fast.

You can also cut holes in aluminum with a jigsaw with nice metal blades do you have to pre drill the holes to get the saw blade through you also have to tape over the material you working on. I would also suggest using the quality jigsaw because the cheap ones have too much wander in the shank that holds the blade.

 

[jimmyjimmy19702010]

If the whole idea of using Aluminium for a custom box is for the fun of using metal to build a box, then go for it!

If you want to use it to house speakers then just be prepared for a less than ideal audio result. Any custom box that is housing (well driven) 8 inch drivers and up with have to contend with big vibrations.

BT signals are also much weaker than cellular phone signals. Some BT equipped class D amps have an external antenna. You could try having a small, external stubby antenna to improve the BT reception.

You could install an internal timber frame inside the aluminium cabinet to address the vibrations issues maybe.!?

Looking forward to seeing what you come up with if you do decide to go ahead with the build.

 

[Reli]

It would definitely look cool. Imagine getting the aluminum adonized any color you want. Kind of like Diamondboxx.

But I think the biggest problem would be comfort and convenience. Metal corners hurt when you bump into them. You would need to put a very good bevel on those edges to make them more comfortable.

You could line the entire interior with Dynamat to reduce resonance. Maybe add a couple wood braces as well. You could also do what Diamondboxx does and add a bass port made from a simple ABS plumbing tube from Home Depot.

 

[Superduper]

I have been wanting to do an aluminum box for a few years now. True, a metal box does make it more difficult to receive radio signals and do bluetooth. On the other hand, a sealed metal enclosure also will make for a very quiet (electrically speaking) box as well since outside interference is almost all but snuffed out. Radio signals can be ported through external antennas. Even bluetooth needs an antenna so porting it outside is definitely a possibility. Resonance can be a problem if the aluminum is too thin, but if the panels are stiff enough to resist, might not be as much of an issue as one might think. Only one way to find out... presuming it will be an issue is just presumption.

 

[Lasonic TRC-920]

This has also popped into my head. I think the resonance issue could be handled with some dynomat.

I would really love to see this project!

 

[trippy1313]

It'd be fun to try. I hadn't thought on anodizing, that might be cool to have done. I was wondering about the tuner and bluetooth antennas how they'd be affected by an aluminum case. If they were able to be connected to an external antenna could that likely help?

My biggest concern is the weight. I'm trying to think before attempting what it would possibly weigh with everything.

All the stuff to get it to work today is probably less weight and size than the stuff they used back then. But if the case alone is truly 10-12 pounds itself... add whatever battery configuration, speakers, etc... I'd love it to weigh close to a classic boomer.

 

[Reli]

Silver carbon fiber speakers would look pimp in an aluminum box

 

[jimmyjimmy19702010]

I’ve been on the look out for years for an ABS plastic case for future builds. The problem is finding a box big enough. The biggest one I have found that doesn’t incorporate a hinged lid is 34 cms x 27 cms x 11 cms. :
https://www.aliexpress.com/item/-/32548438990.html

This would be ok for a micro build. If an ABS box can be sourced that is more like 60 cms x 45 cms x 25 cms in size or bigger, then we will have the perfect ‘Boombox sized’ option for builders who don’t want to build their own.

 

[trippy1313]

That'd be perfect if we could find that Jimmy.