Making your own speakers may not be the most cost effective project, especially if you don’t have the raw materials and tools lying around already, but it can be a pretty satisfying project.
For this set of speakers, I decided on the standard rectangular bookshelf form. I opted for full-range drivers from parts-express.com so that I didn’t need to fuss with crossover components inside the cabinet, and I wasn’t keen on attaching a subwoofer to the set anyway. This kept the cost lower and the project simpler.
For the walls of the cabinet, I used 3/4″ thick birch plywood for the frame walls, and 1/2″ plywood for the front and back panels—really thick plywoods made for some tedious hand sawing.
I opted for a vented design with 1″ x 4″ port tubes, so the inner walls just needed some acoustic foam and did not need polyfill.