Parts Express Blast Box User manual

Blast Box Portable Bluetooth Speaker Kit
Thank you for purchasing the Blast Box Portable Bluetooth speaker kit. This speaker kit was
precision cut using CNC machinery for the best possible fit and finish. With a little time and
patience, your finished product will pro ide years of enjoyment. Please follow the following
instructions for the best possible results.
Follow this link to see the Blast Box assembly ideo: https://youtu.be/XgAn3-kQjNQ
Follow this link to hear a Blast Box sound test: https://youtu.be/Ofy5A0m4x Q
Suggested tools and consumables:
Drill Rag or paper towels
Screwdri er Solder
Wood clamps (you can ne er ha e too many of these) Soldering iron
Sanding block and/or electric finishing sander Hot glue gun
Wood glue Polyurethane glue (Gorilla Glue)
Wire stripper/crimper Wrench/pliers
Package contents:
First, empty the contents of the package and re iew parts to ensure e erything has been included and
is in good condition. If any parts are missing or damaged please contact our customer ser ice
department at 1-800-338-0531.
Note: Crosso er components may be substituted with parts of equal or higher quality depending on
stock.
Main Components:
a) TPS3116D2 Class D 2.1 Bluetooth 4.0 Amplifier Board with Filter and Volume Control
b) Dayton Audio DCS165-4 6-1/2" Classic Subwoofer 4 Ohm
c) Dayton Audio DS215-PR 8" Designer Series Passi e Radiator

d) Dayton Audio LBB-3 3 x 18650 Lithium Battery Charger Board/Module 12V
e) 2 x Dayton Audio ND25TA-4 1" Titanium Dome Neodymium Tweeter
f) 2 x Dayton Audio DSA90-8 3" Designer Series Aluminum Cone Full-Range Dri er 8 Ohm
Crossover Components:
g) 2 x Dayton Audio DNR-8.0 8 Ohm 10W Precision Audio Grade Resistor
h) 2 x Dayton Audio 1.00mH 20 AWG Air Core Inductor Crosso er Coil
i) 2 x Dayton Audio 0.10mH 20 AWG Air Core Inductor Crosso er Coil
j) 2 x Dayton Audio DMPC-1.5 1.5uF 250V Polypropylene Capacitor
k) 4 x Dayton Audio DMPC-3.3 3.3uF 250V Polypropylene Capacitor

Enclosure Components:
l) Top Panel
m) Amplifier mounting panel
n) Front panel
o) Back panel
p) 2 x Vertical internal baffles
q) 2 x Horizontal internal baffles
r) 2 x Side panels
s) Bottom panel
Wire, Hardware, and Other Components:

t) 1 ft. Speaker Gasketing Tape 1/8” x 1/2"
u) 1 x 3-Pack 18650 2600mAh Li-Ion Flat Top Battery
v) 1 x Clear Acrylic Mounting Plate for Metal Panel Mount DC Jack
) 1 x Clear Acrylic Mounting Plate for TPS3116D2 Class D 2.1 Amp Board
x) 5 x 0.110" Female Disconnect
y) 10 x 0.205" Female Disconnect
z) 5 x #8 (16-14) Ring Terminal
aa) 8 x Pea ey Nylon Shoulder Washer
bb) 6 x Adhesi e Rubber Feet Dome Shaped
cc) 1 x 15VDC 4A AC Adapter Power Supply with 2.1 x 5.5mm Plug Center Positi e
dd) 4 x #8 x 1/2" Deep Thread Pan Head Screws Black
ee) 4 x #6 1-1/2" Coarse Thread Cabinet Screws

ff) 10 x #8 x 3/4" Deep Thread Pan Head Screws Black 100 Pcs.
gg) 30 x #6 x 3/4" Deep Thread Pan Head Screws Black
hh) 2 x Dual Binding Post 1 Red 1 Black
ii) 1 x 2.1mm Metal Panel Mount DC Jack
jj) 10 ft. JSC Wire 18AWG Red/Black Zip Power Speaker Wire
kk) 10 x Cable Ties 5-1/2” Natural
ll) 2 ft. Consolidated 22AWG Red Solid Hook-Up Wire
mm) 2 ft. Consolidated 22 AWG Black Solid Hook-Up Wire
nn) 5 x 1/4" x 1-1/2" Zinc Fender Washers

Enclosure Assembl :
1) First, before gluing anything, do a dry fit of the enclosure to familiarize yourself with the
parts and assembly. This will also gi e you a chance to ensure that all pieces ha e been cut properly.
2) Next, set the enclosure parts out on a flat le el surface and ensure that all pieces are free of
dust and debris.
3) Due the design of this enclosure, it can easily be assembled in one sitting, using as little as 4
clamps. Start with the back panel lying flat with the dadoed side up, as shown.
4 Apply a small bead of glue to the inside of the rabbeted edges of all joining surfaces of the
back, bottom, and side panels. Then set in place applying enough pressure to ensure glue is spread
through each joint (some glue squeeze-out can be expected).

5) Apply a small bead of glue to the inside of the rabbeted edges and dadoes of all joining
surfaces of the horizontal inner baffles, ertical inner baffles, back, and side panels. Then set in
place applying enough pressure to ensure glue is spread through each joint (some glue squeeze-out
can be expected).
6) Apply a small bead of glue to the inside of the rabbeted edges and dadoes of all joining
surfaces of the top, ertical inner baffles, back, and side panels. Then set in place applying enough
pressure to ensure glue is spread through each joint (some glue squeeze-out can be expected).

7) Apply a small bead of glue to the front of the amp mounting panel. Keep at least 1-1/4”
away from the o al shaped opening, as shown. Also apply a small bead to each outside edge of the
amp mounting panel. Then set in place as shown, applying enough pressure to ensure glue is spread
through each joint (some glue squeeze-out can be expected).
8) Apply a small bead of glue to the inside of all the rabbeted edges and dadoes on the front panel.
Then set in place on the rest of the enclosure, due to the tight fit a firm tap may be needed. Apply
enough pressure to ensure glue is spread through each joint (some glue squeeze-out can be expected).

9) Finally apply clamps so that e en pressure is applied to all glued surfaces. With just 4
clamps, begin by using 2 clamps to apply pressure to the top and bottom panels. Next, use the other
2 clamps to hold the side panels together. Then remo e the first 2 clamps from the top and bottom
and mo e them to squeeze the front and back together near two corners. Finally, remo e the 2
clamps from the sides and mo e them to squeeze the front and back together near the two remaining
corners. Using a damp rag or paper towel wipe away any glue squeeze-out on the outside of the
enclosure (excess glue on the inside is fine). Allow to dry according to the glue manufacturer's
recommendations and remo e clamps.
10) Sand and finish enclosure to your liking. See our web page for examples. Finally, peel the dome
shaped adhesi e rubber feet from their backing and place one near each corner on the bottom panel (only
4 will be needed)

Crossover assembl :
Point-to-point iring diagram
Follow this link for a step-by-step video showing the Blast Box crossover assembly:
https://youtu.be/eJ feKH8Te8
11) Arrange the components as illustrated in the point-to-point wiring diagram abo e so the leads
can be connected together as shown. Take careful note of the component type and the alue of the
component. (The crosso er schematic is pro ided at the end of this assembly guide.) If you would like,
the crosso er can be mounted to a 3" x 5" board to make handling it a little easier, which will fit
perfectly inside the enclosure.
12) Connect the leads of the components as shown in the diagram by twisting them together or
creating interlocking "hooks" with the leads. Double check your layout to ensure all components are
in the proper location and connections are correct.