mklett33

Step 3: Molding the Door Panel Shape: With a foundation for our speakers we now need a foundation for everything to mount too. In this step we mold the shape of the door panel to use it as the back side of the door pod. Tools Needed: Resin Mixing Cup Mixing Stick Pigment Chip Brushes Chop Mat Painters Tape With a complete foundation and mold of the door panel we are ready for the next step: Step 4: Forming the Pod Shape: We will use similar tools as step 3 to create the actual shape of the pod. The only additional items needed here are glue, and grill fabric. With the shape complete, it’s time to get things smooth and prepped for paint or vinyl. Step 5: Body Filler Smoothing: We will use body filler to smooth the panel. Duraglass is a high build filler that adds a small amount of strength but will not crack. Tools Needed: Spreaders Rage Gold Duraglass With the panels smooth we are nearing completion of the panels!

In this tutorial write up we will be covering how to create some awesome door panel pods that will add a custom look to your install, allow you to integrate multiple speakers into a door panel, and allow you to control the mounting position of the speakers. Note that while these are in fact door “pods” that are not actually permanently bonded are made as part of the door panel itself, there are many techniques within that could be used if you were in fact planning on creating door “panels” from scratch. Let’s begin! Step 1: Woodwork and Templates: In order to have a good foundation for our door pods we want to make awesome speaker rings. The video above covers many of the details needed. Take your time with this step as clean woodwork is essential to having a good foundation to create the door pods. Tools needed: Router Jig Saw Jasper Circle Jig Flush Trim Bit Rabbeting Bit Foam Tape LTP Stapler and Staples Upon completion you should have great looking speaker templates that are prepped for molding into the panel. Step 2: Reverse Mounting Speakers: This step is not essential in terms of design, but it is important to have a plan for exactly how the speakers will mount. The last thing we want is to make these amazing door panels and use wood screws to secure the speakers that will become loose with time. Take a look at the fasteners we used here instead. Tools Needed: Drill and Bits Marker When complete your speakers will be ready to mount securely to your pods.

Then it was time for vinyl: Here is the finished product:

As you will see in the following two videos the pods recieve body filler treatment and are then wrapped. I wanted to fill some of these gaps: So I protected the panel: Applied body filler: So now there is extra: Once I sanded it down things looked a lot better: I then prepped the rings for vinyl by running them on the rabbeting bit:

With the techflex cut I am now going to terminate the end where the RCA's are close to one another. I cut a 1.5" length of 1.5" heat shrink, and shrink it to size: Now we have this end to clean up: I put two more lengths of techflex over the separate wires like this: And once again cover with a 1.5" length of techflex: Now all that is left to do is terminate the seperated ends: And here is our finished product! Now there are some added touches we can add to the wire to finalize. Watch the following video to see!

Tech Flex is something that I have always loved using in my installs. It not only helps to protect the wire I find that it has a number of other uses as follows: Color Code Wire Bundle Similar Wires Link the Wire to the theme of your iinstall Refresh otherwise "bad" looking wire In this thread I would like to share my process for covering a wire in techflex as well as some of the techniques I have learned for working with it. In this example I am going to be bundling two RCA cables together to make a 4 channel run that is tied together at one end and seperate at the other. It looks like this when complete: Lets begin: To start I prepare my wire and tech flex. The wire I am using is KnuKonceptz: I find that I have to use .75" Tech Flex for anything RCA's. For other size wiring follow the following chart: 8 Gauge - 1/8" 4 Gauge - 3/8" 0 Gauge - 1/2" If you are bundling multiple wires you can measure the diameter and determine the size needed by knowing that techflex expands to 1.5x its original diameter. So 1.00" Techflex could be used for up to 1.50" size wire or bundles of wire. Here is a spool of the 3/4" In order to begin sliding the RCA's through I hold them like this. It may help to actually tape them together like this. Also if you are running multiple separate wires through you will want to tape them together temporarily. To begin passing the wire through I bunch up the techflex and then allow it to pass over the wire. Like this: This is shown better in the video link that I will post below, but you get the idea. As you work down the length of the wire with the swollen section the techflex will move down the wire. You will have to do this multiple times to cover the length of wire you want to cover. Once I got to this point I stopped because i wanted to have the RCA's be able to separate based on the locations of the amps. I did not cut the length of techflex before starting because with the expansion of the techflex itself the length can change. Its best to apply it then cut. Now its time to cut the techflex. I have a nice heat knife I use from WireCare.com :: Your Cable Management SuperStore! but you can also heat up an exacto knife and use it. This is shown in the video. You must use one of these methods or the techflex will fray, the ends must be melted to each other.

Thanks Aaron! Glad you like it. Im not sure what you mean in your first question. I do lay the fiberglass while it is still on the panel so that it doesn't warp and change the shape too much from the factory panel shape. Thanks! Thank you.

Here is step #4, forming the surface of the door pod. In this video I test out Steve's Sunflash resin.

Started molding the shape of the door panels.

Thanks!

Got to do some more work on this build: In this post I will teach you how to reverse mount speakers and also how to use threaded inserts: I found the threaded inserts at my local hardware store, I have also seen them at Home Depot, Lowes, and Menards. I really like them as you don't have to be concerned with stripping out the wood if you have to remove the screws to remove the speaker and put it back in. They are very easy to use as I will outline in the video at the bottom of the post: Here is a picture of what they look like once mounted fully, I chose to use a washer as well to have more of a surface for the screw to hold against. With the reverse mounting I found this configuration to be very appealing to the eye. I really like how you cant see any of the mounting holes, just the outer most part of the surround. In the video below I outline how to install the threaded inserts, as well as how to reverse mount a speaker. Enjoy!

Hey guys! I recently picked up a KMH 8 from DAD to see what the hype was all about. Overall I found this subwoofer to have quite the level response and to have the ability to handle quite a large amount of power. It also comes in at a great price point that can't be beat. I will let the video do the talking!

Hello! For those of you who don't know me my name is Mark and I am the man behind "Car Audio Fabrication" on YouTube. I have posted build threads before (like this one: http://www.soundsolutionsaudio.com/forum/topic/57168-video-build-log-fi-bl-rockford-fosgate-focal-knukonceptz-tip/ ) and if you have ever seen one you know that I love to mix in "How To" Videos throughout the build that describe the process and show each step. This build will be no different! well, it will a little bit because I am going to try to mix in a lot more pictures for your viewing pleasure! I love to help other car audio enthusiasts young and old, newb and veteran, so if you see something you have a question about ASK! The Vehicle: Chevy Duramax 2500 HD Extended Cab (Will add pics soon) The Gear: Alpine Type R's 6.5" Component Speakers 10" JL Audio W3 Knukonceptz wiring Wirecare.com wire protection products Alpine MRP-M500 Alpine MRP-F300 The Install: Custom Fiberglass Door Pods with Vinyl Wrapped Inserts to accent interior and match sub enclosure Custom Fiberglass Subwoofer Enclosure (Specs to Follow) The Goal: Quality sound that integrates well with the vehicle and requires little to know permanent vehicle modification. (No cutting of panels allowed!) My Goal: Teach the readers of this thread as much about the fabrication of the pods and sub enclosure, as well as the install as I can. Let's begin! We started with collecting some of the gear, the ownder of the vehicle wanted to re-use his Alpine Component Speakers and JL Subwoofer, I talked him into purchasing a MRP-F300 which is the exact same foot print as the MRP-M500 and will allow for a really clean install. The components: The sub: The amplifier: (Still need pics of the 4 channel) I then determined what was needed wiring wise and put in an order with my friends over at Knukonceptz.com: I am very excited to use their new product the KNF-60, we were one of the first to get a production unit and I was really impressed with using it in a different build so I decided to get one for this one as well: All of the wiring in this build will be protected by Techflex which I recieved from our show sponsor WireCare.com . They really have some great products and the "snake" style techflex will look awesome with the tan and black truck. Its crazy how many colors of this stuff there is! Now the EXCITING stuff! I made these outer insert templates with a series of router techniques and skills, I discuss them in the video. The idea is they will insert into the pod and can be wrapped with a different material or painted to accent the install. Here you can see I will mount the woofer from the rear, and the tweeter is flush mounted: Finally I added some low temp plastic around the base template so that the top insert could lay flush. I show how I do this in the video as well. Well thats all for now, let me know what you think! Add this thread to your book marks and check back often!

Hey all, Ever wondered, what weight chop mat should I use? What resin do I need? How much hardener (MEKP) do I need to add to the resin? What is it is hot? What if it is cold? Whats the best way to use fiberglass and add strength to something? Wonder no longer my friends... As i gear up for my door pod build I have been amassing some more fiberglass fabrication products. These products are typical of what you would see in any car audio install that involves fiberglass show I wanted to share them with you, along with an explanation of each and some answers to questions I see repeatedly online! Enjoy! Also, here is a wonderful table that allows you to better understand how much MEKP to add to your mix.

Thanks! Keep it loud ! I ran the BL for a bit, it was loud and sounded nice, but it was just too much lol. I guess part of me decided that I wanted to show people how impressive an 8 can be with a proper box design and install, so I switched up the game plan. Thank you for watching!

Will do thanks for watching, I am glad you liked it! Sounds awesome man, once its done shoot me a PM on here or make a post on my facebook page, facebook.com/caraudiofabrication . I would love to see it! Thank you! Haha Thanks!

Well the build is pretty much done! I would love to know what you think! Thanks for taking the time to watch! (Click the picture for the video) ~Mark

Comments? Just curios what ya'all think

In this weeks episode I review how you can create a false wall in order to further complete an install. Using a false wall can allow you to utilize an enclosure that is simple, but yet obtain a finished product that looks very custom and integrated within the vehicle. I would love to know what you think! Thanks for taking the time to watch! (Click the picture for the video) ~Mark

Thanks man! Thats really cool dude, I have a whole playlist about amp racks, be sure to watch it! Its just a hat. If SSA sent me one I would wear it too.

Without a good understanding of the proper way to wrap a subwoofer enclosure, applying carpet can be a daunting task. Allow me to solve your problems as I teach you how to rap... er I mean WRAP a sub box! If you enjoy be sure to check out my plethora of other videos! (Click the image for video)

Pics dont work for me, check out my playlist on youtube though, lots of stuff you may want to use.

Been awhile since I updated my build log. Basically every step of my build is outlines in my videos. A brief description is above each video. How to make a sub box with a circular saw instead of a table saw: How to cut a perfect circle for the subwoofer hole: How to Add T Nuts to secure your speakers: How to make the box unique: This video is a MUST SEE

Thank you!

Start saving for a router, by far the most powerful tool (IMO)