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Custom Car Audio Boxes - Subwoofer Enclosures: Don't just any old box them TURBOBASS THEM!

Infinite Baffle "Enclosure"

The simplest enclosure type is an infinite baffle or free air system. Note: Free-Air™ is a trademark of Stillwater Designs (Kicker) In this system the woofer has the front of its cone isolated from the back of its cone by mounting the woofer to the rear deck or on a board placed across the back of the rear seat.

Advantages of this design include simplicity, minimal occupation of space and lower cost due to not having to have a box type enclosure.

Disadvantages of this design are a larger power requirement, difficulty (sometimes extreme) in completely isolating the two sides of the cone from each other, and slightly less accurate sound reproduction.

The simplest box type system is a sealed enclosure. Here a woofer is mounted in a completely sealed box that isolates the front and rear waves of the woofer.

Advantages of the sealed design include ease of assembly, more lenient box size requirements, excellent transient characteristics, high power handling, and a typically smaller enclosure.

Disadvantages are less efficiency (requires more amplifier power) than vented enclosures and less low bass as compared to a properly tuned vented enclosures above the port tuning frequency.

Ported (Vented) Enclosure

Vented enclosures are similar to a sealed enclosure in design except that they add a “port” that is a certain length and a certain area around. This port, usually a length of PVC pipe, is tuned to a certain frequency by variation in the two parameters of area and length. By adding this port, the rear wave of the cone motion is used to reinforce the front wave. When done properly the subwoofer system becomes more efficient than a comparable sealed enclosure above the port's tuning frequency. However, below the port tuning frequency the woofer will become unstable and "unload" causing the woofer to oscillate violently, leading to premature woofer failure when driven with excessive power.

Advantages of this design are increased efficiency and a lower frequency extension above the port tuning frequency.

Disadvantages are a more complex design, a larger enclosure as compared to a sealed design, lower power handling, and slightly less transient accuracy.

The most complex design of the common enclosures is a band pass system. The purpose of the band pass system is increased efficiency over a small range of frequencies. This design also helps filter out unwanted midbass and upper frequencies. There are variations on the band pass design known as orders. The simplest design is the single reflex (4th order) in which a woofer in a sealed enclosure fires into a vented enclosure.

Dual Reflex Bandpass
(6th order) Enclosure
Series Tuned Dual Reflex
Bandpass Enclosure

There are also dual reflex designs (6th order) in which both enclosures are vented and series tuned designs in which the woofer and first vent fires into the second vented enclosure.

Advantages of this design are a high efficiency over a small range of frequencies and some filtering characteristics.

Disadvantages are decreased frequency response, less accurate reproduction, extreme complexity in design and assembly, larger enclosure size, greater woofer unloading and decreased power handling.

Isobaric Loading

Another enclosure design that you may hear of is isobaric. Isobaric is not actually an enclosure type but a woofer loading method. Isobaric loading can be used in conjunction with any of the enclosure types, except perhaps infinite baffle. Isobaric loading consists of two woofers coupled together by a short enclosure which is only long enough to prevent the two woofers from striking one another. The woofers may be mounted face to face, back to back or front to back. It is important however to have the woofers firing in phase with one another. In order to accomplish this with the woofers firing front to front or back to back one of the woofers speaker leads must be reversed with respect to the other woofer.

Isobaric loading is usually used when space is at a minimum or a maximum number of woofers wish to be used in a certain volume of space. By isobarically loading the woofers, a box of only half the size of a one woofer box is needed. For example, if a 12" woofer requires a two cubic foot box, the same 12" woofer isobarically loaded only requires a one cubic foot box. The cost of this design, other than doubling the woofer cost, is a reduction in the subwoofer system efficiency by three decibels (if both woofers are given the same power as a single woofer), which is equivalent to halving the amplifier power. New, small box subwoofer designs have all but negated the need for isobaric loading in car audio and it has fallen out of popularity.

Advantages of this design are increased linearity in the speaker movement, lower space requirements, and increased power handling.

Disadvantages are increased cost, increased design and assembly complexity, and decreased efficiency.

You should also check out Advanced Enclosure Design and Fabrication. It covers designing enclosures using free computer software, maximizing the output of a subwoofer system, building the box like a pro and testing the output using inexpensive equipment.

Advanced Enclosure Design and Fabrication

Advanced Enclosure Design and Fabrication focuses exclusively on designing and fabricating subwoofer boxes for car audio installations. This DVD is designed for the enthusiast who wants to be able to take any woofer and design and build the best box match for it and the vehicle it's going into. We took the easiest and lowest cost techniques and combined them with the knowledge of a fourteen year installation veteran to create a video that shows you how to design and fabricate your own enclosures like a real pro. You'll learn the same techniques, software and materials the pros use to make top quality subwoofer enclosures.

This DVD covers three of the most popular enclosures. The first is a vented (ported) enclosure with a round port. This enclosure is rectangular and very easy to build even for those without any experience. The enclosure is first modeled using free enclosure design software. Then the enclosure side dimensions are calculated automatically using another piece of free software. Finally the cut sheet for the wood is optimized and printed out to take to the lumber yard (again, free software is used).
The second enclosure is a more complex bandpass enclosure that's popular for producing high SPL numbers over a range of frequencies (rap, hip-hop, etc.). The vent on this design is the less often used rectangular port. You'll see how to make the transition from using round ports to the more stylish rectangular port. You'll also learn how to easily calculate the proper vent length when adding corners to the vent. The enclosure is also modeled and laid out using the three free pieces of software detailed above.
The final enclosure is a simple sealed design but in a wedge or truck box shape. This enclosure is also used to show how professionals get the "no seam" look in their carpet and coverings. This is a must know technique if you want to take your enclosure building skills to the next level. The enclosure is also modeled and laid out using the three free pieces of software detailed above.

All three projects use free software for the design. It's recommended that you have access to a table saw if but it's not absolutely necessary. Here are some of the other installation topics and techniques you'll learn that will help you save time, money and aggravation.

Materials and Tools

  • Enclosure materials to use
    • Wood type and thickness
    • Port materials
    • Fasteners and adhesives
    • Covering material and enclosure hardware
  • Tools needed for assembly
    • Hand tools
    • Power tools

Enclosure Fabrication

  • How to get the wood cut for free
  • Three different tools you can use to cut the wood
  • Proper layout of the enclosure screws (and what type to use)
  • How to get perfectly centered holes every time
  • Fabricating ports
    • Simple round ports
    • Rectangular and square ports
    • What to do when the port is too long
    • Instant bonding glue that will eliminate drying time
  • Creating wedge (truck box) style enclosures
  • The importance of bracing
  • How to carpet your enclosure like a professional
    • What glue to use
    • What carpet to use
    • How to cut the carpet to get perfectly flush edges
    • Carpeting inset ends for a professional finish
  • The importance of the proper damping material
  • What type of screws to use to secure your subwoofer (using the wrong kind can cost you big points in a competition)
  • The formula for adding 1/3 more effective volume without increasing the enclosure size
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