This isn't really a "how to" considering I didn't take a lot of pictures, and I don't really know what I'm doing, but people can learn from my mistakes and what I've learned in the last year.

First mess up, didn't use any mold release between the tape and laying down the mat. Usually people use wax or some spray, even spam? I don't know, but I f#cked that part up.

Trimmed the panels down. Used non-hardening clay to angle the baffles. Since I'm using small baffles with relatively light drivers, and low depth, the clay held the shape well for aiming, and everything. If your using larger drivers then clay may not suffice.

I propose a toast:

to 2-part expanding foam.

I sorta forgot about the endothermic reaction during the expanding foam's curing, it got hot enough that it started melting the clay. Luckily the curing process was extremely fast, and didn't actually allow the baffles to be moved in any way.

catalyst ratios on notecard, wax paper for laying down mat, and applying resin first.

I'm using 3/4 oz chopped mat in multiple layers, and general purpose polyester based resin.

On one of the kicks, I laid down one single piece of mat (already wet'd out), but it didn't want to contour around the bottom edges. So once it cured I had to cut the bottom edging all the way around, and do strips for the seam.

On the second kick, I used pieces, and since the 3/4 oz mat is so thin, it was easy to maintain a smooth surface, even with adding more and more layers on.

Tomorrow is sanding, one coat of resin+cab-o-sil, and sanding. I have to wait a few days for primer and paint to show up. In the mean time I'll mount the kicks, and make sure everything works as planned.

Edited February 10, 201213 yr by stefanhinote

Looking good man. What made you use the expanding foam instead of just building a bracket then stretching fabric over it then resin and mat layering from that?

Very cool bro. I never saw expanding foam used like that.

Are those Dayton Audio mids? RS-100 I love Dayton Audio drivers.

Edited February 10, 201213 yr by edouble101

Awesome Stefan! One of these days we will get together man. We both switch up our gear so often it is hard to time it right. It is funny that we will both be running the same sub stage. Good luck with your build I REALLY look forward to hearing it.

Looking good man. What made you use the expanding foam instead of just building a bracket then stretching fabric over it then resin and mat layering from that?

It's incredibly easy to shape, and I don't have to deal with wrinkles in the fabric.

Very cool bro. I never saw expanding foam used like that. Are those Dayton Audio mids? RS-100 I love Dayton Audio drivers.

You just have to be careful you use the right type of foam or the resin can eat it.

The mids are actually hat l4s. I know right? I heard them in a setup about a year back, and absolutely loved the sound. I'm sure there are other drivers that are half the cost, and perform just as well, but I knew for a fact that I should like the l4s.

Awesome Stefan! One of these days we will get together man. We both switch up our gear so often it is hard to time it right. It is funny that we will both be running the same sub stage. Good luck with your build I REALLY look forward to hearing it.

Every few months it seems! Once I finish the front, in a few months I'll probably redo the rear area, and perhaps get a ported box built.

I'll let you know when it's up and rolling through. I still have to do the a-pillars!

Careful with the Cab-O-Sil, Colloidal Silicone Dioxide is bad for your respiratory system

Careful with the Cab-O-Sil, Colloidal Silicone Dioxide is bad for your respiratory system

I have a 3m respirator with carbon filters, hopefully that will work.

Thanks for letting me know.

Edited February 10, 201213 yr by stefanhinote

They look very nice Sir ...

Looking Good Stefan! Hopefully you get the sound your after. Good luck with finishing detail. I am rooting for you!!

Looking Good Stefan! Hopefully you get the sound your after. Good luck with finishing detail. I am rooting for you!!

Me too. Have you used any solvents for eating away foam by chance?

Okay never mind, the urethane foam is designed to not be eaten away by any solvents.

Edited February 10, 201213 yr by stefanhinote

I have not. I would try acetone before gasoline though. Do a test on something other than the pod. Otherwise try to carve most of it out.

Can I dissolve this foam once it has fully cured?

No. This foam is designed to be completely solvent resistant once cured. Gasoline and acetone will not cause any destruction of this foam. Please prepare ahead of time by covering any objects/areas that you do not want to come in contact with this highly adhesive product. If you do happen to spill some foam and it cures you will have to either sand or scrape the product away.

That looks soooo smooth and fluffy.

I have not. I would try acetone before gasoline though. Do a test on something other than the pod. Otherwise try to carve most of it out. Can I dissolve this foam once it has fully cured? No. This foam is designed to be completely solvent resistant once cured. Gasoline and acetone will not cause any destruction of this foam. Please prepare ahead of time by covering any objects/areas that you do not want to come in contact with this highly adhesive product. If you do happen to spill some foam and it cures you will have to either sand or scrape the product away.

Yeah, oh well, a dremel and screwdriver can work wonders.

Plus I'm doing IB, so it shouldn't be the end of the world.

That looks soooo smooth and fluffy.

haha.

Sanded for twenty minutes. Coat of resin + cab-o-sil.

Those look sweet. Much more rounded than you normally see.

Those look sweet. Much more rounded than you normally see.

Nothing wrong with HAT

What are you doing with the tweeters?

Nothing wrong with HAT

What are you doing with the tweeters?

Well normally id put some small cheapo tweets on the dash/apillars to raise height, but I already have the hds, there going off axis in pillars. Total overkill, but I have lots of room for crossover points.

I just installed the kicks and l4s. Haven't done any tweaking, had to drive across town. So far I like it. The stage height is actually really high, but I've already started the pillars, so ill finish them, otherwise I don't think id use any to be honest.

The kicks are also pretty much sealed right now. When I pull them back out for paint, ill open up the back, and they should really shine.

Awesome. I can't wait to see your pillars.

I take it that you can run the I4 full range? If so you should be able to use a high xover point

Are you building covers for the underside of you dash? Even if it its cardboard it will help.

Awesome. I can't wait to see your pillars.

I take it that you can run the I4 full range? If so you should be able to use a high xover point

Are you building covers for the underside of you dash? Even if it its cardboard it will help.

I started the pillars before I had the foam, so im not sure how they'll turn out yet. may redo them with foam.

I have the l4s crossed at 350hz right now.

My car has a flat panel under the dash, its thin wood wrapped in a soft material, so I guess the Volvo is cutting me some slack.

Your Starting to look like a pro.

Your Starting to look like a pro.

I wish.

Edited February 11, 201213 yr by stefanhinote

How are you doing the pillars? any pics?

How are you doing the pillars? any pics?

The regular way, baffle and dowels, wrapped in cloth. I laid a bunch of mat over the entire pillar. Once I sand it, ill probably have to use some body filler.

Ill post pics when there done, heh.