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 ColumBUS
A.k.a.: The Liquid Chef
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| posted on November 11th, 2004 at 10:46 AM |
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awesome stuff
what sort of stereo are you looking at? brands etc.
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Dasdubber
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| posted on November 11th, 2004 at 09:28 PM |
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Speaker panels are from Glass Action (formerly Innovations in Fibreglass):
http://www.vwinnovations.com/bug.html#speaker
Stereo includes one pioneer 12in sub, two pioneer 3 way 6x9s, two pioneer 5 1/4 splits, kenwood cd head unit (not sure of specs), two kenwood amps
(350 and 500W).
When I bought the gear (at a sale way back), I didn't know much about car audio (still don't know a hell of a lot), but in hindsight I should
have:
A) gone with a sub designed for an enclosure not free air,
B) wouldn't have gone with 6x9s plus a sub (will try and isolate the 6x9s in their own boxes to avoid distortion from the sub for now),
C) should have gone with 6 1/2 splits up front
D) should have gone with head unit mp3 compatible.
However, since the project has cost so much thus far, I cannot just start again so I'll use all the components and see how they go. It still should
sound pretty nice....hindsight is a wonderful thing isn't it! :puke
[Edited on 11-11-2004 by Dasdubber]
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Dasdubber
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| posted on November 12th, 2004 at 08:31 PM |
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Fired up the router to make a sub mounting ring tonight...here it is half way through (router ensures ring is perfectly round.
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Dasdubber
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| posted on November 12th, 2004 at 08:32 PM |
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Here is the ring complete - inside was cut with jigsaw since this edge won't be seen.
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Dasdubber
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| posted on November 12th, 2004 at 08:33 PM |
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Slowly but surely the rear sub enclosure (sort of an enclosure since it is a free air sub) and 6x9 mounts take shape.
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nbturbo
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| posted on November 12th, 2004 at 08:57 PM |
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JESUS-is there nothing you can't do,and always top notch-way to go.Keep up the lessons for us web students.
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Dasdubber
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| posted on November 14th, 2004 at 07:55 PM |
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Well, after having a look around the vw show at the gold coast this morning, thought I'd better pull the finger out and do some more work. Started
the sub box - spent lots of time measuring and scratching the noggin trying to figure out how to get it to fit under the rollcage, be able to put it
in and out without removing the cage, how to not interfere the mallory coil that will be mounted on the inside of the firewall.
Anyway, marked up the sides of the box on 16mm MDF. The sub will be angled towards the back seat but not right up against it.
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Dasdubber
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| posted on November 14th, 2004 at 07:57 PM |
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Apologies in advance for going overboard with the pics - I just thought some people may be able to learn how to do something from the pics rather than
just an explanation.
Here is the side panel rough cut with a jigsaw (remember to use dust mask because the $hit in MDF is not good for your lungs). A little bit of
material was left alongside the marked lines.....
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Dasdubber
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| posted on November 14th, 2004 at 08:00 PM |
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.....so a flush cutting bit on the router table could be used (with a straight edge [factory cut edge] as a guide). This way a perfectly straight cut
can be achieved so the box is perfectly sealed (although putty/silicone will be used as well).
Two nails temporarily hold fence in place (doesn't matter as holes will be filled or covered anyway)
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Dasdubber
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| posted on November 14th, 2004 at 08:03 PM |
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Just make sure you feed the material in the right direction so it doesn't kick back. Perfect edge every time (as long as your guide is straight!).
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Dasdubber
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| posted on November 14th, 2004 at 08:06 PM |
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Here you can see the box half assembled - edges glued and screwed. The angled portion at the back lower edge is so the box can fit hard against the
firewall without butting against the rolled (curved) lower corner on firewall.
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Dasdubber
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| posted on November 14th, 2004 at 08:09 PM |
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The box will have a top (which I ran out of time to do), but the sub ring will be perched atop so the fibreglass will have a more interesting shape to
follow than a flat board. This is the first time I've done this so I'm learning as I go.
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Dasdubber
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| posted on November 14th, 2004 at 08:11 PM |
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Here it is temporarily in place - work to continue this week. The extra material on the base is so it can be bolted down to the body (I hate f'ken
thieves). :cussing
Breather box (custom stainless steel) is being made at the moment as well.
[Edited on 14-11-2004 by Dasdubber]
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Dasdubber
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| posted on November 14th, 2004 at 08:16 PM |
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For green57, a couple of pics of the rear apron brackets. This week or weekend I'll pull one off and measure it up for you. I keep forgetting to do
it sorry! Its hard to get decent pics when it is on.
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Dasdubber
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| posted on November 14th, 2004 at 08:18 PM |
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They are pretty easy to make - I used some 5mm thick flat steel, I think 30mm width. I just made a template out of thin cardboard, pushed it over the
bolt holes so you know where to drill them, notched the lower edge so it could fit on the body without hitting anything.
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warb
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| posted on November 14th, 2004 at 08:24 PM |
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nice.. have new apron on order soon, engine is now in... looking good..
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Dasdubber
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| posted on November 18th, 2004 at 10:03 PM |
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Sorry to bombard more boring pics (may help someone like green57 when doing a removable apron). Here is the bracket off the left side:
Length 250mm
Width 30mm
Thickness 5mm
It is pretty straight forward to make, just measure up the distance between the two lower mudguard bolt holes and go from there.
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Dasdubber
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| posted on November 18th, 2004 at 10:07 PM |
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The notch is there to clear the lip on the body (you'll know what I mean when you have a look under your own car). Once you work out where the holes
need to be drilled, drill them out large enough so the bracket actually sits flush against the body with the threaded bolt inserts (which you should
have drilled the thread out of out already) acting as dowel pins as such.
Once you have the bracket in place you can weld the nuts on (the welding on these will be improved before they are powdercoated).
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Dasdubber
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| posted on November 18th, 2004 at 10:07 PM |
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Last picture....the whole process really is quite simple...just lots of trial fitting and measuring required before you start cutting/welding
anything.
[Edited on 18-11-2004 by Dasdubber]
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warb
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| posted on November 18th, 2004 at 10:16 PM |
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:beer
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Dasdubber
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| posted on November 21st, 2004 at 08:38 PM |
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This weekend involved some more work on the sub box/speaker tray. Here you can see the completed sub box (middle section) as well as outer skeleton
which will provide the framework to house the 6x9's.
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Dasdubber
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| posted on November 21st, 2004 at 08:42 PM |
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The joints of the box were siliconed inside to provide an effective seal (should be pretty much air-tight for effective sub performance). If you make
a sub box yourself, allow at least a day before installing your sub (for use) as the vapours from the silicon can eat away the material of the sub
(foam/rubber).
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Dasdubber
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| posted on November 21st, 2004 at 08:45 PM |
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The 6x9 mounting rings were hot glued in place (had to make sure the angle was symmetrical!).
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Dasdubber
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| posted on November 21st, 2004 at 08:48 PM |
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You can now see how it is all coming to shape.
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Dasdubber
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| posted on November 21st, 2004 at 08:50 PM |
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Pioneer sub in place with Kicker cover, and two pioneer 6x9s. None screwed in place - just checking fit etc.
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Dasdubber
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| posted on November 21st, 2004 at 08:52 PM |
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Started to staple the stretchy material into place as this gives the shape the fibreglass will form.
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Dasdubber
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| posted on November 21st, 2004 at 08:54 PM |
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Ran out of time to finish the staple job - may have to put a few more MDF skeleton pieces in place to give it the desired shape.
Hopefully next weekend I'll have the fibreglass done.
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ruckus
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| posted on November 21st, 2004 at 09:41 PM |
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Are you going to copyright all of this? I have a feeling there'll be a few duplicate setups appearing over the next few months  |
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Dasdubber
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| posted on November 21st, 2004 at 09:49 PM |
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They say the best form of flattery is imitation!
Ah well, thats the risk you take for detailing the progress of such a project before its done. Don't really care as long as someone doesn't claim
the idea as their own 
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DIY-DUB
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| posted on November 22nd, 2004 at 11:36 AM |
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dasdubber thats a sweeet lookin enclosure i wanna c a pic of it in the car when finished |
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