How to repair subwoofer voice coil

How to Repair Subwoofer Voice Coil

Subwoofer Voice coil repair

Many people enjoy loud music. They damaged their subwoofer because loud music requires more power. If you overpower the coil, you will usually damage it. When the voice coil is damaged, The subwoofer does not produce sound, or you hear the sound, but with distortion. 

Damaged vs New voice coil

Voice coils differ between different subwoofers. Sometimes you can buy voice coils from the market, but sometimes you can’t. Today, we will discuss how to repair subwoofer voice coil by hand. We demonstrate a step-by-step guide on How to fix a blown subwoofers‘ voice coils in the following guide. Let’s get straight into it.

Required Equipment

  1. Insulated copper wire 
  2. Toluene 
  3. Yellow Contact Adhesive
  4. Slow-drying epoxy resin
  5. Scissor
  6. Masking Tape
  7. Thin wooden sticks
  8. X-ray’s plastic film
  9. A clean cloth
  10. A piece of aluminum foil
  11. Kraft paper
  12. Tip spear scalpel
  13. Heat Gun 
  14. Mold with the same diameter as your voice coil.
  15.  Winding Machine

Steps to Follow

Step 1: It is first necessary to position the mold in the winding machine and tightly tighten it.

How to repair subwoofer voice coil - step 1

Step 2: Measure the width of the damaged voice coil.

How to repair subwoofer voice coil - step 2

Step 3: You should measure the aluminum strip face over with a tolerance of 2 millimeters.

How to repair subwoofer voice coil - step 3

Step 4: Using a pencil or screwdriver, bend the aluminum strip. You must face the silver side inward when you make your ring.

How to repair subwoofer voice coil - step 4

Step 5: Once the mold has been placed, the aluminum strip is wrapped around it and taped down. After the mold is placed, Wrap the aluminum strip around it and tape it down.

How to repair subwoofer voice coil - step 5

Step 6: On the bottom of the aluminum, place both x-ray strips. Strips of X-ray paper make it easier to remove the aluminum from the mold.

How to repair subwoofer voice coil - step 6

Step 7:  Now paper the epoxy resin. You need to use equal parts and mix them well with thin wooden sticks. It is also a good idea to add epoxy solvent if you will not be using toluene. Remix it again if necessary.

How to repair subwoofer voice coil - step 7

Step 8:  As soon as you reach the top of the masking tape, pull down the copper wire.

How to repair subwoofer voice coil - step 8

Step 9: We apply epoxy resin over the entire top of the aluminum when we roll up the wire.

How to repair subwoofer voice coil - step 9

Step 10:   After you’ve wound the wire, it’s time to crimp it. Make sure that the first turnaround finishes at the wire’s beginning point. The machine should be started after the first turn is completed, and the wire turns should be rolled up without leaving any space between them and without that turn mounted on another turn. It should be perfect winding.

How to repair subwoofer voice coil - step 10

Step 11: Apply the epoxy resin over the copper winding after you roll up the first winding wire layer.

Repair subwoofer voice coil - step 11

Step 12: Once the epoxy resin is applied over the copper winding, turn the wire over the first layer of winding again. Remember to wind the second layer wire the same way we wound the first layer wire. With masking tape, we secured the second layer and with a wire cutter, we cut the same length wire as the starting wire with the help of a cutter or scissors.

Repair subwoofer voice coil - step 12

Step 13: You can now leave it to dry for 24 hours or you can use a heat gun to dry it. Remove the bubbles with a cloth as wire and resin are heated with the heat gun.

Repair subwoofer voice coil - step 13

Step 14: Must remove varnish from wire ends with a lighter.

Repair subwoofer voice coil - step 14

Step 15: Sanded the wire with sandpaper now.

Repair subwoofer voice coil - step 15

Step 16: The beginning wire is the positive and the end wire is the negative.

Repair subwoofer voice coil - step 16

Step 17: Now you can also check the positive and negative through a digital voltmeter.

Repair subwoofer voice coil - step 17

Step 18: Remove the x-ray strips from the bottom of the aluminum strips now. Now we need to remove the voice coil very carefully from the mold.

Repair subwoofer voice coil - step 18

Step 19: Measure the width of the voice coil collar now.

Repair subwoofer voice coil - step 19

Step 20: Now we apply the yellow adhesive contact across the surface of the voice coil collar and dry it for a while.

Repair - step 20

Step 21: Also apply the yellow adhesive contact on kraft paper. After the glue has dried, we place the kraft paper on the collar of the voice coil. After going around we put the wires over the paper. Apply some yellow adhesive contact on the wire and place the kraft paper and let it dry. Also, make sure that they are isolated.

Repair - step 21

Step 22: Then use a cloth moistened with toluene to clean the remaining glue.

Repair - step 22

Step 23: Now apply the solder paste to the end of the coil wire and weld them.

Repair - step 23

Step 24: You need to make sure that the voice coil is matching the speaker.

Repair - step 24

Step 25: Now you need to connect the positive wire to positive and the negative to negative. (stating of winding is positive and ending of winding is negative)

Repair - step 25

Step 26: If you want to check that the wires you connect are right then use a battery or cell and connect positive to positive end and negative to negative end. If the voice coil moves upward then you connect the right wires.

Repair - step 26

Step 27: Now your voice coil is ready, and you can replace the voice coil.

Step 28: Reassemble and Fix Other Parts as you remove them.

Enjoy your music and subwoofer now. If you still have trouble following these steps on how to repair a subwoofer voice coil or if you don’t understand them, you might find this video useful.

MuhammadAli

Hi, this is Ali. I have been an enthusiast of speakers especially subwoofers. So, I am finally going to throw my experience out for you guys.

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