<PERSON>
Introduction: <PERSON>
Hey everyone what's up!
So this is the Jack O'Speaker which is a Bluetooth Speaker crammed into a Jack O'Lantern.
In this case, the Jack O'Lantern is 3D Printed and made out of Orange PLA instead of Pumpkin.
I could make this out of an actual Pumpkin but it won't last long so a better idea is to make the whole thing from Plastic.
Inside this Jack O' speaker, there's a 40W Stereo Bluetooth Amplifier Board connected with a 4 Ohms speaker powered by a 12V Lithium-Ion battery pack.
The goal or motivation for making this Speaker was to prepare a Halloween-themed BT device that can be kept anywhere at the home, and we can play creepy music on it to add some ghostly vibe in the air.
Also, this setup is loud because of the higher wattage the speaker draws as I'm using a super kool speaker which has been salvaged from an old Home theatre system.
In this Instructables, I'm gonna show you guys how I made this project in few easy ways.
So let's get started!
Supplies
Stuff I used in this built-
3D Printed parts
* Pumpkin Model made from Orange PLA
* Pumpkin Upper part made from Green PLA
Other Stuff
* Audio Module
* Battery Pack 12V 5.2Ah (with BMS attached)
* 3mm LED
* 10K Resistor
* Diode IN5399
* DC barrel jack
* Rocker Switch SPST
* Wires
* M3 Screw x4
* Speaker 8Ohms
Step 1: Prologue
Audio Module
Now the Heart of this project is the Audio Bluetooth Amplifier module which is this "XY-P40W".
ThisModule can work between the Voltage of 5V and 24V but I will be using a 12V Lithium-Ion battery pack to powering this module.
This module runs Bluetooth 5.0 and has dual speaker output.
Also, the output power of the setup I'm using is around 20W which is with a 4 Ohms speaker at a 12V Power source.
It comes with a Volume Adjusting knob but I won't be using that in this project.
I got this module from PCBWAY's Giftshop, link is here- https://www.pcbway.com/project/gifts_detail/Stereo...
Speaker
As for the Speaker, I'm salvaging a great speaker from my old home theater set.
The Speaker I'm using is a 4 ohms woofer and its built quality is just awesome. I have a total of 10 speakers with me so i will be making a bunch of these Pumpkin speakers I guess. (image is attached of the whole home theater system which I bought in 2010)
Anyway, a normal 4 Ohms speaker will work as well, if you want to make this project then you need to edit the mounting holes for the replacement speaker.
Step 2: PLAN
The plan here is simple, Jack O'Lantern shape will contain or house the Speaker, Audio Module, and Battery Pack.
I will be adding a switch between the battery and the Audio module for turning the setup ON\OFF.
Also, for charging the battery pack, I will add a DC Barrel Jack with an IN5399 Diode in series and an indicator LED that will indicator the charger Plugged IN.
As for the 3D Printed part, I will be using the generic pumpkin shape and modify it for BT Speaker conversion.
Step 3: CAD Design
To start this project which involves a Pumpkin Model, I have to model a pumpkin.
Unfortunately, Modeling a pumpkin is a very long process but you know what's easy and really a good tool for this kind of stuff, Tinkercad.
* From the Tinkercad's Part library, I selected the Jack O'Lantern Model and then set its dimensions as required.
* Then I exported the Pumpkin Model from Tinkercad to Fusion360 Directly as both of them are Autodesk products and hence they are connected so we can send any file made in Tinkercad to Fusion360 which is a cool feature.
* In Fusion360, I first cut down the Top side of Pumpkin so I could add a speaker inside it.
* For Elevating speaker position a little bit I added a part between Base Pumpkin Speaker. (later I made this part from green PLA which gives this project nice dual-color contrast)
* AfterFinalizing the Model, I exported its 3mf file for 3D Printing.
Step 4: 3D Printed Parts
As for the 3D Printing settings and color profiles, I used two kinds of PLA in this project. 485