This post is going to hit a nerve! People get very sensitive about this subject.
Plywood (left) and MDF (right) Subwoofer Enclosures
There are two main materials that we build boxes with. Plywood and MDF so here are the pros and cons of both.
Five Pro's of MDF:
MDF is heavy! You want heavy and dense for your sub box!
MDF is "inert" -- meaning it will not resonate and color the sound. It also does not expand and contract as humidity changes.
MDF is true to size! 3/4" MDF is 3/4" While plywood is often NOT
MDF is easy to Machine. If you are dong complex router work use MDF, it will not tear out like Plywood.
MDF is CHEAP! That is not reason to use MDF, it is a great material for the above reasons. So think of the lower price as a bonus.
Carpeted MDF Enclosure
Five Pro's of Plywood:
Plywood is light, up to 50% lighter than MDF.
Plywood looks awesome! If you know how to finish and stain wood then you can make some amazing works of art out of plywood.
Plywood is inert -- just like MDF the box will not color the sound. Especially if you use a high-quality plywood.
Plywood plays well with wood screws. It is less prone to splitting and the layers do a good job of holding on to screws.
Finally plywood is strong! How strong, check out this video!
Five Con's of MDF:
MDF is HEAVY! Yes, I listed that as a pro. But heavy boxes break backs! Plus they add weight to your car.
MDF does not like screws. It splits if you don't drill a piolet hole and you need coarse-grain screws or they will pullout.
MDF is hard to paint. This goes against conventional wisdom, but it is true. Especially the edges. You need to seal it before you paint it. But the best thing to do is cover it with carpet or veneer.
MDF generates nasty dust. Fine particles that get everywhere, like your lungs. You do need a dust mask when you do this kind of work.
MDF can't get wet! It will swell! Also, don't feed it after midnight.
Plywood Subwoofer Box
Five Con's of Plywood:
Plywood is expensive, at last the good stuff is.
You are not using good plywood. I see a lot of boxes online that use construction grade plywood and even if you opt for "birch" or other hardwood plywood from the local home center these are not hardwood. These have a decorative hardwood veneer, the plys are all pine.
The plys are visible, and they can be ugly.
Plywood is undersized -- it is typically 23/32" of an inch. So you need to take that variance into account when building your box.
It is hard to make it look good -- you need some experience with stain or the box will look nasty.
This is the legendary, and reliable Jasper Circle Jig. It is a must-have, and the best tool for DIY speaker cut outs. For those that don't like making Jeff Bezos even richer, consider purchasing one from Taylor Tool Works.
Go ahead and spend the money on a quality bit. You will use this, along with the circle jig and plunge router, to plunge into wood and cut holes for speakers, ports, and terminal cups. A straight bit will work, but these spiral bits plunge much better. Again, check check out Taylor Tool Works as an alternative to Amazon.
Even though I have a great table saw I still use my circular saw quite often. You can break down plywood and MDF to manageable sizes to use on the table saw, or just use your saw with a straight edge or edge guide. Go ahead and get a cordless one. The brand does not matter, get one that uses the same battery as your cordless drill.
This may be my favorite beginner/DIY tool. With a little practice you can get straight, accurate, and repeatable cuts. Plus this thing is CHEAP. Check out my video review:
Some people prefer "glue and screw." I prefer to use a brad nailer. I use Ryobi simply because they were the only cordless platform with an affordable cordless nailer. You can use a pneumatic one, but you will also need an air compressor, plus hosses and accessories.
Yes you DO need hearing protection. I have been using 33M Worktunes. These let you listen to music while you work, plus they are bluetooth so you can take phone calls.
Circular Saw:
