Yes - The 15" boxes and the 12 and
horn boxes that I currently use I built. In the past I have built foldback wedges and musical
instrument cabs as well.
The actual process of designing the box is much more difficult than actually constructing it. Speakers boxes are much more than just a just a
speaker in a box and you need to design the box around the
speaker. You need to decide if the box is to be closed or ported, trapezoidal or cube, cross-over or not (then there are the variations on the cross-over) the need for internal bracing
etc.
Most of the information that you need is listed on the specs sheet that comes with the
speaker (or on the box). Some manufacturers actually offer “free” box designs for their speakers as well, which takes out a lot of the
leg work.
The good news is that now there are lots of software applications that you can use to not only design your box, but also
plot the performance before you even
pick up a tool. I have played with a lot but WinSpeakrz seems to be one of the best.
There is a demo version that seems to have most features working. There are also a host of web sites that run through how to
build a
speaker box.
The other consideration is the hardware (corners, grill, handles
etc) and for the speakon connectors, I would mount them onto recessed panel (Penn Fabrication will carry all the hardware but others may know better). Again, you will need to find the speakon plugs from others as I am in Australia. And whilst I recommend our country as a tourist destination, it is a bugger of a trip just to
pick up some speakon connectors!
I would go with plywood over particleboard as it is stronger. The other question you need to ask is how are you going to finish the box? Carpet, vinyl, paint? More things to consider.
The electronics side is very simple and you might need a friend that is a chippie more. Once you have your box sizes worked out, you may be able to get a local business to run the ply through their table saw for you. Nice clean straight cuts will certainly make life easier for you.
Hope this helped and please ask if you need more info.