Allan Clarke DIY Subwoofer

Making the End Caps

The End Caps were made from 18mm thick MDF sheets, which I purchased from the local hardware store. These are very hard to cut into perfect circles, and as I don’t have a Router I marked out the outside diameter of the circle to be cut using the outside of the tube as a template and roughly cut to size using a Jig Saw. I took the 4 circles together with the cut Formatube to a local cabinet maker who cut the End Caps to the inside diameter size - so they were a perfect fit for only $50 AUS. Cheaper than hiring a Router and making a Circle Jig.

Using Ron Stimpson’s idea, I laid out the 10” woofer and ports onto one End Cap. I then marked out the hole for the driver and the two ports, which are 90mm OD each, and cut them out using my Jig Saw. I drilled out a slot for the Binding Posts and then used that as a template for the next End Cap, thus making sure both were exactly the same. Once that was completed, I glued the End Caps together making sure that everything lined up.