Modify/split Sub woofer and built in amplifier into separate boxes.
Was one big box
One of the reason for the "smart table" was the large lower shelf. Planned was putting sound system sub woofer box on the shelf. The area that sub woofer use to occupy on floor was absorbed in remodel. However sub woofer box is about 1/4" too tall. Even if it fit between, depth of sub woofer box would use all the shelf space.
So splitting the box, separating the amplifier and mount remote from speaker box. Then shorten the speaker box.
Here I've removed speaker and amplifier started the cut to separate. About 4" inside from rear is end of "speaker" box. The sides continue back where another rear section of MDF is that amplifier is mounted to. Cutting box flush to end speaker box end panel leaving it intact. Put a new end on amplifier box.
And separated. Again this will get a new back.
Then cut top off of speaker box to shorten. Cut box leaving excess the on lid that I'll remove later. I ended up running box thru saw again to cut closer to port hole. A little caution on first cut as its close to port, check on table, it fit but was tight. After removing another 1/8" perfect
Amplifier is a nice stand a lone unit.
Checking distance for new back. Was going to insert a piece of mdf (partical board) but not enough depth.
Used an 1/8" sheet of luan glued & nailed to face of box edges. Held panel back bout 1/8" so its edge not showing. Also, not shown, is 1x2 block across top, glued to inside corner. 2 mount screws will go thru to spread load/weight to box. Lower screws will just go thru panel.
Bored several holes across the bottom and 2 at the sides for a lot more air. Covered with screening. There are some air slots in amp panel, but more air is better-this thing generates a lot of heat
Added a flanged male receptacle from inside of box. Yes its a power plug from old computer. Hardwired amplifier speaker output will plug into this. Speaker is wired with 2 hot inputs, one ground.
Glued and screwed a block to further retain receptacle. Solder on speaker leads, the profusely embedded with hot glue.
Glued and screwed on lid. I had scribed a line and put a bead of caulk on box and lid behind port tube that I cant get in to once lid on. Once lid attached the two beads contact, though I was able to 'tool' to smooth and ensure contact. Re caulked the remaining inside joints and tube. I also caulked the joints externally,
Hardwired female end of cord to amplifier output.
Mounted amplifier box to table. Soon as I attached amp panel realized I won't be able to easily reach the power switch.
Back in the shop wired in a switch to top of box. Its after the factory switch to utilize existing pilot and fuse. Reinstall amp on table. Nice- red off, green on (you can see the red glow of the original pilot lamp when on). At night when lights are off the green glow is notable at night, the red not so much.
Though the power is switched by the sound system I've never left it on stand by, well intentionally, but often forget to turn off. It may go days without being used, no reason to have energized. Also the sub woofer on occasion use to go off about 3:00am, picked up feed back from something and start humming LOUDLY. Rattle the whole house. Hasn't done it since reworked but I think maybe more to do with just moving speaker/amp from its old location. Don't know.
Making new Grill. Recover with new cloth and cover black box with paneling matching table.
I had cut & reglued the original plastic grill to match new box height but...One, the grill stood away almost 2", second it had this odd sculptured angle never did like, like a wedge. Plus needs new fabric, had a hard time buying fabric for something I don't like.... So cut a piece of 3/4" ply to make a new flat face grill.
While paint drying started covering the box. When I assembled TV cabinet I screwed up attaching the back. Ordered an other to replace. Decided I could salvage some of the original paneling (actually final covered cardboard) to get enough to cover speaker box, almost. Had to get creative to cover top and sides. But got it.
Came out pretty good, better than I hoped. When on tables shelf a lot less noticeable than a big black box. :) plus some room in front. Pictures will not show color I see. But used some nice brown speaker cloth. Don't now why any pictures the colors so off. Regardless were happy with it. I replaced the speakers badge, not sure why.
Honestly its brown....
More importantly its installed and working again. Sound is not as muted/muddy as it was? I didn't know what effect raising off carpet would have. Maybe its using table or being between the chairs-don't know but actually sounds better which I was only hoping it didn't get worse.