Sound System

UPDATE: I discarded the entire concept of these speaker enclosures. Speakers going into the doors. ----- First I taped down two layers of carpet so that the spacing would work out when finished - distance to the floor.

2015823

Then placed the kick panel in and covered the floor area with aluminum foil, shiny side out and taped off the joint. No foil on the kick panel, as it will be part of the speaker box. The foil will pull off the back after it's fabricated.

2015487

Laid down a layer of fiberglas mat on the floor and on the kick panel, and soaked down with two inch brush. Decided I hate the "random directional" mat type, as it comes apart very easily (brand name was Bondo").. don't use it.

2015427

Another layer and more resin - total of 24 ounces of resin...

2015687

This is actually the passenger's side box, partially fabricated. Getting those sticks the correct length and hot glued in is a little tricky. Took 4 or 5 tries to get position, angle, tilt to work out where I wanted them. Orange marking is where the back part is to be cut out and ground smooth before the t-shirt goes on. Marking on kick panel side is where the t-shirt will be hot glued to the panel.

2015412

Then placed a 3/8 dowel in the "cutout part" of the oval to get the speaker pointed up between the driver and passenger's heads, and hot glued some "legs" on the oval mount piece, made of sandwiched 1/2" and 1/4" fiberboard. Also removed the entire "rough" box and trimmed and sanded the edges to outside dimension size.

2015742

Test fit. Still no low frequencies...ahahah

2015

Cut up one of my old tee shirts (front had holes and gasket sealer stains), and hot glued onto the back of the trimmed out fiberglas "fabrication".

2015364

Cut out the center and hot glued the speaker edges on the inside of the mount, stretching the shirt material to minimize wrinkles.

2015768

After applying one coat of resin on the shirt up to the edge of the speaker grill indentation, cut the "dry" material out.

2015448

Cut out the "dry" part of the shirt so the edges can be glued down.

2015506

Edges rolled in and glued, not resin, to the wood frame. Then applied two more layers of mat and resin using pieces about 2" by 4" to go around curves. This time I used the "woven" mat, which is much more well behaved.

2015186

Things are taking shape! Both speaker boxes are fabricated, wired, and working fine. Wires for dash pulled up and tied off behind the dash, switches all installed and working. Next the 1951 trunk hinges will be installed (hidden - not on the outside as the stock is). The orange wire is for "third brake light", which I prolly won't install.

2015

Cut-out pattern to install rear speakers in package rack. Had to mount the speakers at an angle to miss the new trunk hinge mounts that are just under the flat part in the center, lower part of this picture. New Dremel tool cutting wheel is just great for cutting thin metal !

20150619150202

Package rack cut-outs for speakers.

20150627175414

Underside of the package rack with speaker reinforcement ovals.

20150620151757

Top side of the package rack ready to be covered with white rolled and pleated material.

20150620151828

1,600 Watt power amp....sounds pretty good..Mounting under the front seat. Refer to the "Painting the car" for the final design and installation of the speakers.

20150821152739

Subwoofer volume control mounted under the dash - right under the radio volume knob. Also USB charging port and mini input plug. Small vertical LEDS are security system flashing when armed.

20160920173452