Using the woofer size, you will need to calculate the necessary size of your enclosure. (See measurements in Resources section.)
Avoid building square enclosures or using parallel surfaces during your construction. These designs produce unpleasant sound frequencies. Instead, angle the box so the largest side is the front side. This way the sound waves will travel forward and out of the box.
Find out the specifications of your woofer, usually referred to in terms of "Q" and "V" ratings. This is important to finding out the volume of your speaker enclosure. To get the volume, multiply the Q rating by the V rating. Then you have the volume of your DJ speaker box.
Durability of the wood that you use is very important to the quality of sound. Porous wood resonates poorly with varying unpleasant frequencies. Do not use plywood or particle board unless it is to line the inside of your structure, but is not the main source of support. Baffle board is best for sound and lack of distortion.
Using the saber saw, cut the appropriate size holes for your speakers into the baffle board before screwing the boards together.
Assemble your box using the power drill and dry walls screws. Use the 90-degree clamp to ensure sturdy structure at the right angles.
After your basic box design is complete, you will want to increase sound quality with a few finishing touches. It is very important to attach metal carrying handles to your enclosures.
Brace the corners of the box with rubber casters that will mold to the shape of your enclosure and protect it from damage.
Line the inside of the box with carpet to protect your speakers.
Paint or apply a veneer to the outside of your enclosure to give it a more appealing appearance.