Introduction
Many low-cost Bluetooth speakers like the TG-113 stop performing well after some time. The plastic enclosure limits bass, the charging circuit often fails, and the sound starts feeling weak and hollow. However, the internal components of these speakers—especially the speaker driver, amplifier board, and passive radiator—are actually quite capable if used correctly.
In this project, we completely redesign the speaker by removing all parts from the TG-113 Bluetooth speaker and installing them into a custom-built wooden MDF enclosure. A properly designed MDF box dramatically improves bass response, sound clarity, and overall loudness. We also upgrade the charging system using a TP4056 module, making the speaker safer and more reliable.
This tutorial explains the entire process step by step, exactly how the project can build.
Components, Materials & Tools Required
Electronic Parts Recovered From TG-113
- Full-range speaker driver
- Bluetooth amplifier board
- Passive radiator
- Rechargeable battery
- Internal wiring and connectors
Additional Electronic Components
- TP4056 lithium battery charging module
- Type-C or Micro-USB female charging socket
- SPST power switch
- External Bluetooth antenna
- 5 push button switches
- LED indicators for charging and power
- Connecting wires
Mechanical & Construction Materials
- 6 mm MDF board
- Fevikol or Heatax adhesive
- Feviquick
- Hot glue sticks
- Sandpaper (medium and fine grit)
- Screws (wood or Zipsum type)
Required Tools
- Hand saw or MDF cutting machine
- Drill machine
- Cup drill bit for speaker holes
- 5 mm drill bit
- Screwdriver
Step 1: Disassembling the TG-113 Bluetooth Speaker
Begin by carefully opening the TG-113 Bluetooth speaker enclosure. Most of these speakers are clipped or lightly screwed together, so open it slowly to avoid damaging the internal parts.
Remove and separate the following components:
- Speaker driver
- Bluetooth amplifier board
- Passive radiator
- Battery
- Power switch, antenna, and wiring
Inspect each part to ensure it is working properly. These components will form the heart of the new speaker system, so handle them carefully.
Step 2: Designing and Cutting the MDF Enclosure
To achieve strong bass and solid sound, we use 6 mm MDF board. MDF is dense, vibration-resistant, and ideal for speaker enclosures.
Cut the MDF board into the following dimensions:
- Side Left & Right Panels: 7.5 cm × 6.8 cm
- Front & Back Panels: 24 cm × 8 cm
- Top & Bottom Panels: 24 cm × 7.5 cm
Accuracy is very important at this stage. Straight and precise cuts ensure:
- Better air sealing
- Stronger bass performance
- Easier assembly
- Professional finish
Take your time while cutting.
Step 3: Making Speaker and Passive Radiator Holes
Take the front panel and mark the exact positions for:
- Speaker driver
- Passive radiator
Using a cup drill bit, drill perfectly round holes. These holes must be tight-fitting so that there is no air leakage, as air leaks reduce bass performance.
- Fix the passive radiator using Feviquick
- Fix the speaker driver using hot glue
Ensure both components are sealed properly around the edges.
Step 4: Assembling the Wooden Speaker Box
Now start assembling the enclosure by attaching:
- Left panel
- Right panel
- Top panel
- Bottom panel
to the front panel using Fevikol or Heatax adhesive.
For extra strength, add 2 cm MDF support strips inside all four corners. These supports:
- Increase enclosure rigidity
- Provide a strong base for screwing the back panel
Allow the enclosure to dry completely before moving forward.
Step 5: Sanding and Back Panel Installation
Once the glue has fully dried:
- Use sandpaper to smooth all edges
- Remove sharp corners and surface unevenness
If the panel does not align properly, sand the edges again until the fitting becomes perfect.
Good finishing not only improves appearance but also prevents unwanted vibrations.
Step 6: Making Holes for Indicators and Buttons
Next, drill:
5 mm holes in the front panel for:
- Charging indicator LED
- Music ON/OFF indicator LED
Ensure the holes are aligned neatly for a clean look.
Step 7: Charging Circuit Upgrade Using TP4056
The original charging circuit on the TG-113 amplifier board is not working properly. To fix this, we use a TP4056 lithium charging module.
Steps:
- Connect the TP4056 module to a Type-C or Micro-USB female socket
- Fix the charging port on the back panel
- Connect the TP4056 output to the amplifier board power input
This modification ensures:
- Safe battery charging
- Overcharge protection
- Longer battery life
Step 8: Power Switch, Buttons & Antenna Wiring
- Install an SPST power switch on the back panel
- Connect an external antenna for improved Bluetooth range
Now connect five push button switches in parallel with the amplifier board buttons:
- Power
- Play / Pause
- Mode
- Volume Up
- Volume Down
Double-check all wiring connections before final assembly.
Step 9: Final Assembly and Internal Arrangement
Place all electronic components neatly inside the enclosure:
- Fix components using hot glue
- Arrange wires properly to avoid noise and short circuits
Finally, close the back panel and tighten all screws securely.
Step 10: Testing and Performance
Turn ON the power switch and connect Bluetooth from your phone or laptop. Play music at different volumes and check performance.
You will notice:
- Deep and punchy bass
- Clear vocals
- Improved loudness
- Portable and rechargeable operation
The MDF enclosure significantly enhances sound quality compared to the original plastic speaker.
✅ Conclusion
This project demonstrates how an old TG-113 Bluetooth speaker can be transformed into a powerful, high-bass, wooden Bluetooth speaker box using basic tools and low-cost materials. By improving the enclosure design and upgrading the charging circuit, the speaker delivers far better audio performance and reliability.
This is an excellent DIY project for electronics enthusiasts, content creators, and anyone who enjoys building practical and powerful gadgets at home.
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