You may be on to something FenixFire. I originally had a 3D printed chassis that had an open, press-fit mount for the speaker in the end. The main part ended up being to flimsy, so I made a PVC chassis with a cap that pressed over the top of the speaker, pinning it against the end of the PVC pipe. It seems I may have obstructed the speaker membrane from vibrating freely, thereby burning the speaker out. Does that sound about right? My son has a saber with the original 3D print chassis and an open press fit speaker mount that works just fine. Ever since I tried the cap-over idea, I've burned out 2 speakers! I'm thinking this may be the cause. Any other agreements to this theory or other ideas?