DIY Bluetooth Speaker With Powerbank

Hello Guys, In this instructable, I'm making an awesome Bluetooth speaker. which also has an inbuilt power bank feature. That means you can also charge your phone and other gadgets using this Bluetooth speaker. So let's make this awesome 2in1 Bluetooth speaker.

Specs & Features:

• Dual 3W Full- Range Speaker(4ohms)
• Passive Radiator For Extra Deep Bass
• PAM8403 High- Efficiency Amplifier Module(Class D)
• Inbuilt 5200mAh Powerbank
• USB Charging
• Bluetooth 2.1
• Long Lasting Battery Backup

Here is the complete tutorial and sound demonstration video.

Step 1: Parts List

We need these following parts to make this Bluetooth speaker.

• PAM8403 Stereo Amplifier Module.
• 3W Full Range Speaker (2x)
• Passive Radiator
• Bluetooth Module
• 2600mAh 18650 Li-ion Battery( 2x)
• Micro USB Battery Charging Module
• 3.7v to 5v Booster Module
• On/Off Switch
• 4mm Acrylic Sheet

Tools List:

• Mini Handsaw
• Rotary Tool/ Dremel(optional)
• Soldering Iron
• Hot Glue Gun
• Wire Cutter
• Masking Tape
• Superglue
• Marker Pen
• Metal File

Step 2: Making the Enclosure

Here I'm using the acrylic sheet to make the enclosure for my bt speaker. This is a pretty good material, it is to cut, bend and sand, it is also so affordable if you compared it with wood or plywood. But in terms of sound quality wood and plywood can provide better punchier bass and crisp sound than the acrylic sheet. You can use any of these options according to your need.

1. Take the measurement of the acrylic sheet for the enclosure then make it with a marker pen.
2. Use your handsaw or jigsaw to cut the acrylic sheet pieces.
3. Place speaker and passive radiator on the acrylic sheet to draw their layouts. Then cut those layouts using jigsaw or handsaw.
4. Use above same method to mark and cut layout for USB port and switch.

Step 3: Sanding the Acrylic Pieces

First, remove the paper cover from acrylic sheet pieces, then rub the pieces with sandpaper to get a smooth and clean surface. later it'll be very helpful while well attach the pieces by superglue.

Step 4: Mounting the Speaker and Passive Radiator

In this step, i'm going to mount the speakers and passive radiator. So follow the below steps.

1. First, apply a thin layer of superglue around the edges of the speaker hole.
2. Then attach the speaker and hold it still for a couple of minutes
3. Repeat the same method to attach another speaker and the passive radiator.
4. Finally, add a thin layer of hot glue around the speakers to make them 100% airtight.

Step 5: Making the Battery Pack

Here I'm using the two 18650 battery to make the battery pack for this project. They're cheap, common and safer than Lithium-Polymer batteries. 18650 batteries are also called vape batteries. If you opt not to order online, just go to your local vape shop and you will be able to find a lot of these. You can also find this battery in old laptop battery or powerbank. I found these batteries from a power bank.

1. First, apply some hot glue on the battery then seal them together in parallel order.
2. Solder wires to make them connected. ( Battery welder is much safer to do this but I don't have this so I'm using soldering iron to do this)

Note: Don't hold the soldering iron for too long on the battery. This could damage the battery or maybe explode.

Step 6: Mount the Battery Pack and the Switch

First, apply hot glue on the battery, then take a small piece of acrylic and attach it with the battery pack. Again use hot glue to attach the battery with the back panel. Take other two small pieces and attach them using superglue. These little pieces will act as the base for the charging modules. Use superglue to mount the power switch, then apply hot glue to attach it permanently.

Step 7: Mounting the Charging Modules

Apply some superglue to mount the charging modules temporary, Then use hot glue to attach them more permanently.

Step 8: Attach the Side Pannels

First, apply a big amount of superglue on both sides of the back panel, then carefully attach the side panels, and hold them until they get stuck properly. At the end apply hot glue to attach them more strongly.

Step 9: The Circuit Diagram

I'll upload the circuit diagram tomorrow. Sorry for the delay.

Step 10: Attaching the Bluetooth and Amplifier Module

In this step, we'll attach all the modules using hot glue. At first, apply some hot glue on the back of amplifier board then attach it to the enclosure like the picture shown above. Similarly, attach the Bluetooth module.

Step 11: Assemble the Front and Lower Panel

Now I'm going to attach the lower and the front panel. Use the previous method to attach the final pieces.

1. First, apply some superglue on the edges of the back panel and side panels then attach the lower panel.
2. Use hot glue to make the joints more strong.
3. Again apply some superglue on the edges then attach the front panel. hold it tightly for a couple of minutes and later use hot glue to attach more firmly.

Step 12: Attach the Final

Before attaching the upper panel we have to solder iron with speakers, correctly solder positive and negative wire with the speakers. Then seal the upper panel using a big amount of superglue. After attaching all the pieces, use your sandpaper or sanding block to get a smooth and clean finish like mine.

Step 13: Further Improvments

You can customize your Bluetooth speaker as your choice. you can paint it using spray colour to give an awesome look. I'll add rubber feet to reduce the vibration.

Thanks for watching this project. I hope you'll like this project. If you like this project then Please do VOTE for me, I really need your support guys and I have a youtube channel(DIY Builder) you can find many projects on my channel.