Car Audio Subwoofer-Custom Installation - Page 2 - Router Forums
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post #11 of 18 (permalink) Old 07-22-2019, 07:21 AM Thread Starter
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So after final mockup, turns out the upper trim panel fits perfectly on each side.....but 3/8" too far apart! Had to cut it in half, take out 3/8" and then dowel it back together......my first ever such attempt. Harbor Freight to the rescue, using Woodcraft supplied longer dowels. Pretty happy with the results, one skim coat of two stage spot putty and the seam disappeared.

The rollbar downtubes run at an angle, so I had to play with the drill press and a 2" holesaw. Ended up starting the hole and then finishing free hand before cutting the lower trim pieces off. They will be fastened to a baffle trim panel I have yet to design; want to wait until everything else is put together to see how it all looks before proceeding.
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Last edited by tulowd; 07-22-2019 at 07:23 AM.
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post #12 of 18 (permalink) Old 07-22-2019, 07:28 AM Thread Starter
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And picked up several yards of foam, matching Ford carpet and real Alcantera (aka Ultra Suede) for the upholstery to begin. This is a very satisfying part of the project, not sending it out, but rather doing myself. Takes long and is hard on the fingers, but I am pleased with the results. The trim panel is getting stitched up in leather; that I cannot do myself.....yet.....some kind of sewing machine is in my future, after the car is on the road.

The upper panel is upholstered around the back top edge and down to just where the baffle will attach. Usually, these panels would all be fully upholstered, but because they need to interconnect structurally and airtight, this was a hybrid assembly and finishing process......aka a real PITA!!
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post #13 of 18 (permalink) Old 07-22-2019, 07:37 AM Thread Starter
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The lower front panel received a dado style groove from my circular saw in order to allow stapling the bottom carpet and top Alcantera in one space, the transition is hidden behind the horizontal lower rollbar.

Keep in mind, every layer of material represents app 1/8" of thickness when fully compressed. This meant having to cut 1/4" off the front of the angled baffle on both front and rear vertical faces, at the appropriate angles. Measure 10x, cut twice. Worked out and fit like a glove, I'm happy to report.

Then finished Dynamatting the inside of the enclosure, and finally permanently install the baffle; followed by upholstering it inside the vehicle. Hardest install and finishing project in my 40 yrs of car audio.
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post #14 of 18 (permalink) Old 07-22-2019, 07:46 AM Thread Starter
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And the final part; over 2 hrs of careful stretching, stapling, cutting and tucking until it was all done. The gaps are perfect, the material is tight and the blind speaker plug receivers are invisible under the foam and Alcantera. They may be used for the final trim piece, yet to be designed and built.

Apologies about the post and picture rampage, but I thought it made sense to detail all these steps, since this is a very unusual project, even in the car audio world. About 90% completed; the last trim piece(s) and speaker install is only going to take a day or two. May decide to build a speaker flush trim / beauty panel; that will have to wait until the car is actually back together and driving.

Next step is to make up and install the two large L+R wiring harnesses, finish the insulation and start the carpet installation. Hoping that, along with the completed upper trim panel will be done by the end of this coming weekend, after I return from Cleveland. Took my son to the Syracuse Nationals this past weekend, simply breathtaking workmanship and ideas galore. Will do a separate post on that.
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post #15 of 18 (permalink) Old 07-30-2019, 09:05 AM Thread Starter
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Weekend was productive, altho it was over 100*F/40*C here, so a bit sweaty lol. Sure glad I didn't have to cut or router any mdf.

Subwoofers now installed and wired, temporary grilles refinished and installed, rear trim panel back from upholstery shop installed. Wired it all up to my test bench 50 ft away and it rocked Dire Straits "Money For Nothing" in 2 Ohm mono from a little Fosgate Punch 45. That would be about 80 Watts rms per woofer, the final setup will be around 325 Watts rms per speaker using some Orion HCCA high current power.

Have to build two more small outer trim panels, and re-upholster the factory inner side panels, but that will have to wait. Rest of the floor pan, firewall and front kick panel areas are now 90% Dynamatted and Dynalinered. Also started making the 3 new wiring harnesses; once those are run the carpet is getting the backing removed, pressure washed and installed. Big progress, at least visually speaking - car doesn't look like a total wreck anymore lol.

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post #16 of 18 (permalink) Old 07-30-2019, 09:54 AM
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Such an installation will produce fuel economy because the air pressure from those woofers will assist the forward motion. The downside is that such a system will upset many motorists especially those sat next to it at intersections.
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post #17 of 18 (permalink) Old 07-30-2019, 07:07 PM
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Nice outcome , looking really good
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I donít always insulate , but when I do .
Ok ,I never insulate
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post #18 of 18 (permalink) Old 11-08-2019, 07:07 AM Thread Starter
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Hey Everyone: Been swamped with non wood and non audio work and travel the last few months - completed some more wiring and prep on the car - actually fired it up about a month ago, so my electrical work and engine prep was all as it should be. Travelled every week in Aug and Oct, so zero got done. Got home from Atlanta last night to see we have received our first dusting of the white stuff. Did pickup another PC690 plunge router and a 10 year old made in Taiwan 14" King Bandsaw with Kreg fence, 6" riser and 6 blades last week. Time to finish winterizing everything and cranking up the heat; then clean up the garage and prep for winter projects. Grabbed another bunch of car audio equipment and traded off 4 of my Orion SX amps for some Focal component speakers as well as another pair of Orion HCCA250s. Should open a store lol. Some pics and videos coming up here and I'll start (or add to an existing) thread on the bandsaw.
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