I loved the Idea of the A-Box by Thodio, but did not want to spend $450 - $850 for the specs I wanted. So my quest to make my own Ammo Can Speaker began. I still spent about $240 on the final product (and a little on failed ideas) but I still came out well under the cost of a comparable A-Box.
Qidi Tech 1 - Dual Extruder
Black and Red
These Grille fit just about any 4" Speakers
As stated in the summary, I wanted to make my own Ammo Can Speaker both to save on costs and because it is fun and rewarding to make your own devices. Originally the only 3D printed parts I had in mind were standoff plates to mount the Bluetooth Reciever and Amplifier Boards on and glue them in place inside of the can. But as the project progressed I discovered a need for different Speaker Grilles.
If you want to know what parts I used in the Electronics shoot me a message.
Trial and Error
I had a couple of Bluetooth Audio Receivers and Amplifier boards on hand, and intended to use those for this project. Unfortunately their quality and compatibility made that undesirable. They would work together but I Was not getting the volume or quality of sound that I wanted.
My original Speakers were Polk Audio DB401's and at $60 a pair they had great reviews. Unfortunately I misread them having an RMS wattage of 85 watts when in truth they only had an RMS wattage of 35 watts. They were not going to stand up to the 2* 100 Watt Amplifier I wanted to use in this project. So I purchased a set of Treo RSX 4.0's at $125 a pair that have an RMS wattage of 75 watts, and a strong endorsement from another buy that builds his own speakers that they will easily handle the 100 Watts that my Amplifier can put out.
This change in speakers is what caused me to print my own speaker grilles. The original set came with a set of grilles that would work for themselves, but the tweeters on the new speakers protruded too far from the main cone to fit under those grilles and they did not come with their own. So I set about finding some to print, and found none that sparked my interest.
So I set about designing my own, but I did not want to just make a plain set. So I looked for inspiration that would work with my limited 3D modeling skills. After rejecting idea after idea, either becuase I thought they would cover too much of the speaker to look good or because I just did not love the designs, I finally settled on Glyphs from Brandon Sanderson's Stormlight Archives series.