quick, cheap loudspeaker repair

During my working days I owned a luxury used car which I purchased with 28k miles on the clock and traded in at 140k miles 10 years later – a decision I regret, since it had character (a big wrestler looking badge for the front grill) and I should have kept and nurtured it.  At about 110k the Bose sound system deteriorated and I arranged for an audioshop to replace the tuner/CD player and, since they said the Bose speakers were incompatible with the new system, the speakers as well.  But I requested they set aside the 4 Bose speakers for me, and for the past 12 years the speakers have sat on a shelf in the garage awaiting their destiny.

I enjoy most music genres and at my log cabin I incorporated various audio components into an acceptable sound system.  Since I did not have speakers, I purchased a pair at the local thrift store – they seemed decent quality.

my thrift store speaker purchase
my thrift store speaker purchase

And for $18.91 what had I to lose.

caveat emptor - sold "as is" with no implied warranties
caveat emptor – sold “as is” with no warranty implied

Actually, $18.91!  I have bought solid wood desks ($6) and paintings ($8 – $25) at the thrift store and been very happy, but then I was able to inspect all the components of the purchase.  A pair of good looking speakers on a shelf unconnected to a sound system can be a pig in a poke – after all why would anyone donate good quality, working speakers.  Desks and paintings you can outgrow but good speakers are always useful.  When I connected the speakers up at the house one worked fine and one was buzzy and noisy.  I suspect the speakers were hammered at high volumes and the one was damaged.

this is the main speaker I replaced - you can see the damaged apron
this is the main speaker I replaced – you can see the damaged apron

So I have  used just the one speaker until, with the advent of hot weather, I had time during mid-day heat to ponder a solution.

And then the Bose speakers came to mind.  Why not replace the damaged speaker with one of the Bose speakers.  But there is a problem – for whatever reason the Bose has a receptacle for 4 speaker wires while I have only 2 to provide.

see the blue box above the specs - it is anticipating 4 wires
see the blue box above the specs – it is anticipating 4 wires

I powered the sound system and tried touching my 2 speaker wires to all combinations of the 4 speaker tabs but no response.  Then I inspected the Bose more carefully and saw that when all was said and done, just 2 wires headed for the speaker.

2 wires lead to the speaker
2 wires lead to the speaker

So I touched the speaker wires from the sound system to these 2 wires and the speaker came alive and sounded decent.  I could have connected the speaker wires to these 2 wires and job finished but I thought it would be more elegant to connect to the interior tabs and I was curious to see how 4 input wires became 2.  So I disconnected the back cover plate.

as I suspected 4 input wires did not simply become 2 wires, there is a circuit board and presumably fancy electronics fineturing the input from the speaker wires
as I suspected 4 input wires did not simply become 2 wires, there is a circuit board and presumably fancy electronics fine turing the input from the speaker wires

Since I am a bit of a novice I decided to commit a travesty and sidestep all the embedded electronics and connect directly to the 2 wires going to the speaker.  I reasoned that the Mitsubishi speaker box had its own electronics and these would have to suffice.  So I made a short extension with connectors for the Bose tabs and a screw on connector for the 2 wires from the speaker box, ensuring I maintained polarity.

But first I had to fit the Bose speaker into the speaker box and since its profile was elliptical/oval it would not fit the rectangular shape of the speaker being replaced.  I needed a template to mark out the shape on the speaker box so I could cut with my Skil jigsaw.  I measured the length and width of the speaker where it would fit into the box , but how to draw an elliptical circle.  Fortunately for my permaculture design course I have been working with Inkscape, freeware software, and so I produced the shape with the software to actual size, printed the circle, then copied it onto cardboard which I trimmed and then used the cardboard to sketch the shape on the speaker box.

the printed elliptical shape on the white paper and the cardboard template to which it was transferred
the printed elliptical shape on the white paper and the cardboard template to which it was transferredI

With the jigsaw I cut out the pattern, the Bose speaker fitted well into the box, I connected the wires and fitted the lid cover and tried it out on my system and it sounds fine.  Job accomplished.

my refurbished speaker - you can see the oval shape of the Bose speaker through the grill
my refurbished speaker – you can see the oval shape of the Bose speaker through the grill

 

 

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