Custom Made 6.5" Front Speaker Enclosures.

[GSXR_J 0]

Hi there guys, just to say ive just got registered and am planning on following this post with photos but have made my own custom made speaker and tweeter enclosures for the front doors from MDF P40 fiberglass and P38. They took a while but were worth the effort and now fit in the standard positions without any door modifications and can be put back to standard when sold.

 

If anyone wants any more advice im happy to help!!! Will try add photos sometime at weekend!

[cybernck 402 1 Cars]

Something like this?

 

http://www.205gtidrivers.com/articles.php?data=i-doorpods

[GSXR_J 0]

No not really, will try and post some pics this weekend so you can get the picture. Still fit in within the standard holes but more compact containing both speaker and tweeter!

[omega 82]

welcome

id like to see some photos as im not keen on the ones in the link

Edited November 26, 2009 by omega

[cybernck 402 1 Cars]

Sounds good!

[GSXR_J 0]

Ok so Ive taken some photos all of my custom made door builds, (the links below-may have to copy and paste into your browser as not sure how to directly link yet!) have look see what you think. Would be nice to have a little feedback, see what people think for my first attempt!!

 

Thanks!!!

 

http://s985.photobucket.com/albums/ae333/GSXR_J

Edited December 1, 2009 by cybernck
The font colour code killed the link otherwise it would have automatically been converted to a clickable link :-). Sorted out now.

[cybernck 402 1 Cars]

That looks very tidy!

[GSXR_J 0]

Thanks, took a while but think its worth the time and effort, not sure if it may look better covered in black or grey alcantera or something similar!

[omega 82]

so how did you do it ?looks neat

[MerlinGTI 3]

Looks good

 

Alacantra FTW \o/ grey

[rtsnoz 0]

These look great. What was involved in making them?

[Galifrey 1]

Ok, they look awesome, really tidy job!

 

[GSXR_J 0]

Thanks guys for the comments - wasnt too sure if they looked too 'pimp my ride' style or not but was only way i thought of to get some larger speakers in without butchering anything!

 

So ok, I will explain all below, step by step...if anyone gets confussed just drop us a messege and am happy to help out or if your in the area drop me a line and more than welcome to pop over and have a nosey!

 

(Didnt take photos along the way-really wish i had now but nevermind!)

 

Things you will need;

*P40 Fiberglass filler (I used 'Davids P40' from Halfords)

*P38 Bodywork filler (Again I used 'Davids P38' from Halfords)

*Fiberglass matting/sheet x1 (Was in same area as P40/P38)

*MDF (12mm)

*Hot Glue Sticks

*Speakers

*Dynamat (Or similar sound proofing)

*Basic Tools (Eg: Jigsaw, sandpaper, glue gun, wet & dry paper (1200), files, screwdriver etc...)

 

(Follows on below...)

[GSXR_J 0]

The Operation;

1.Remove the original speaker grill and speaker.

2.Remove the vehicle doorcard.

3.Clean throughly with thinners etc.. the area around where the speaker sits as well as the area behind as this is where to apply the sound proofing.

4.Apply soundproofing in pieces prewarmed with a heat gun.

5.Work soundproofing in nooks and crannies appling more heat and pressure from a small roller.

6.Refit Door card and repeat for other side.

 

(Repeat each step for the opposite side)

7.Using the original speaker grill as a template, place on top of the mdf and draw around to give yourself almost a square shape. (Note:Place arrow on mdf indicating top and bottom as wont fit any other way round.

8.Unbox speakers and remove round plastic trim which holds the speaker grill. Use this as template on the mdf to draw the inner circle inside the square you have just drawn.

9.Cut out the inner circle then the outer edge of the square. (Should now hold a square mdf with circle inside).

10.Check against the car that it fits into postion nicely. (Should follow the contours/lines of the door card). Adjust if nessersary.

11.Screw the plastic grill housing that came with the speakers to the mdf.

12.Cut a couple of pieces of small mdf triangles to start to play around with the angle of the tweeter of which is required. When happy glue the triangles into place with hot glue. (Tip:Cut double pieces for other side at same time, using each piece as a template)

13.When dry attach tweeter housing to triangles. (Should now be looking at almost square mdf cut out with plastic grill holder in place, circle removed from middle and tweeter housing in place).

14.Cut up stips of the fiberglass matting and with a premade P40 mix start to layer into postion. (Gets quite messy and stringy but have patience and it will prevail!).

15.Work your way all around the mdf placing more and more supporting layers over the plastic trim to the outside edge and to the tweeter housing. By the end should be taking shape.

16.Beware! Next stage is very dusty so probably best to work outdoors. Sand down now rock solid mdf coller with course sandpaper either by hand or with Black and decker mouse or similar till smooth. Dont worry about imperfections or small holes appearing.

17.Fill in any holes or marks with more P40. Leave to dry.

18.Sand down again till happy with finish.

19.Mix up some P38 and start to apply evenly over the entire surface area.

20.Sand down again with course sandpaper by hand.

21.Reapply P38 to anywhere that needs attention.

22.Sand again with course then woking way down to medium then wet and dry till getting almost glass like finish.

23.When dry apply the finish of choice-be it with primer then several coats of paint(Sanding with wet and dry again inbetween coats) or with spray glue and alcantera or leather etc...

24.Place in postion and screw to door frame.

25.Drill small hole through tweeter, and mdf for running of tweeter wires.

26.Fit tweeter and wire up to crossover(Placed in a bag, at bottom of door, zip tied at top to not let any moisture in).

27.Fit main speaker into place and place grill over top.

28.Turn on stereo to check operation.

29.Repeat for other side(Or could complete both sides same time)

30.Turn on, tune in and enjoy!!!

 

Think thats about everything, like i say if anyone wants any more info drop us a line!

 

Good luck!

[GSXR_J 0]

Anyone had a go at making these yet? Any probs drop us a line!