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Monster sound system in a mini


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#1 cooper_shaz

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Posted 18 October 2005 - 08:42 AM

****(29 Nov 2005, New stuff added to the end of this post)*********

I have saw a couple posts and been asked a few times how to build a monster enclosure to house speakers and amps etc.

Also how difficult it is...?

And surprisingly it is not that hard, but does take time..

Follow this post and ask questions for further info

Want an install like this ?

(grabbed the pics to explain and show how it is done)

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#2 cooper_shaz

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Posted 18 October 2005 - 08:43 AM

Under the rear seat

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#3 cooper_shaz

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Posted 18 October 2005 - 08:44 AM

Door pods

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#4 cooper_shaz

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Posted 18 October 2005 - 08:59 AM

Like anything you got to plan this carefully

It is a costly and time consuming thing and without planning you end up making do with the finished results rather than having what you really wanted or end up ditching the whole thing.

How do you plan ??

look around on the net for pics, look at mags like max power etc etc

when you find something that you like the look of (the audio system that is :wink: keep hold of it)

Ask yourself what you want to do with the system ?
What music do you listen to (will affect speaker/amp choice)

How long do you spend in the car ?

Do you want to enter competitions, do you need to keep boot space etc?

Where do you park the car, if it is on the street do you really want components on display ?

What is your budget and how long do you really have to spend on the install..

Think of how long you have in freetime hours to spend on it and divide it by 5..
because you always have other things to do which come in the way.

If you think that in 10 days you could spend all of the days in FULL on the car, for most of us it becomes 2 full days and then some time here and there.

This is why we see so many unfinished and abandoned projects...

Lastly, make sure you have got a decent alarm, you would be stunned at how many folk spend the thick end of 2 grand on a system and do not have an alarm..!

ok so lets get started..!!

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#5 cooper_shaz

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Posted 18 October 2005 - 09:15 AM

ok for this install we want an enclosure for 4 subs in the back and that it..

A couple speakers up front will take care of the mid and treble, the subs will provide the Bass.

Amps mounted in the boot and wires fed through to the front

This enclosure is going to take the place of the rear seats.

What do we need

Material... MDF, cheap, strong readily available and easy to work with.
Hammer
Panel pins
Hot glue gun (9.99 from Argos) handy but not essential
Jig saw
Fabric such as fleece (something that stretches a bit)
Fibreglass resin and hardener, you can get this from Halfords but if it is a big install try find a paint supplier and buy a decent amount (much cheaper)
Sander

measure out the rear seats and cut the bottom and backboards to fit in place of the rear seat. (MDF 15mm)

cut several strips of MDF 2 inches wide and keep them to the side

for the front i want the 4 subs mounts at angles

so cut 4 circles from the MDF (18mm MDF will do) to mount the subs into, then cut them out of the sheet making rings about 3 inches wide

then work out where you want the subs to sit.

Now use the strips of MDF you cut and make legs for the rings to hold them in position

Trim to size and nail/hot glue gun them into place

You end up with something like this

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  • Attached File  pic1.jpg   19.23K   19 downloads


#6 cooper_shaz

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Posted 18 October 2005 - 09:20 AM

Cut 4 more rings out and put them to the side for a minute.

cover the whole thing in fleece or what ever fabric you chose
and pull the fabric into the shape you want.

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#7 cooper_shaz

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Posted 18 October 2005 - 09:26 AM

ok now 4 more rings are needed.

these go on top of the fabric and get screwed down

then the fabric is pulled into shape and stapled/nailed to hold the shape, dont worry too much about creases at this stage, these get filled later.

with the fabric in place we then begin the moulding process.

In a well ventilated place mix resin and hardner together, a cup of resin needs about 4 peas size drops of hardner, any more and it sets too fast.

mix it well and using a paint brush simply paint it over the fabric

once it is all covered and set (tacky) apply the next coat..
about 3 coats is enough

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  • Attached File  pic3.jpg   10.13K   42 downloads


#8 cooper_shaz

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Posted 18 October 2005 - 09:29 AM

leave it to dry for a good few hours, the colder it is the longer it takes..

over night in a warm place is best... this stuff stinks..!! it gives off very very srong fumes, so think about where you are going to do this..

Once dry trim off the extra fabric and you should have something like this.

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  • Attached File  pic4.jpg   21.88K   16 downloads


#9 cooper_shaz

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Posted 18 October 2005 - 09:32 AM

Remove the speaker rings on the outside and trim the fabric so the holes for the speakers open up.

You can take away the support legs now

Turn the enclosure over and apply 4 coats of resin to the underside for added strength. You can also apply fibreglass from the tin here if you want to add lots of strength.

Leave it to dry for a day

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  • Attached File  pic5.jpg   27.69K   11 downloads


#10 cooper_shaz

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Posted 18 October 2005 - 09:35 AM

Now before you go any further have a good look around the enclosure and make sure there is no fabric left without resin on it..

Once happy, test fit the whole thing in the car..

Get the speakers in place. make sure you can put seats back, use seat belts
open close windows etc..

If it needs adjusting this is the time to do it..

All being well you should have something like this

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  • Attached File  pic6.jpg   22.65K   20 downloads


#11 cooper_shaz

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Posted 18 October 2005 - 09:38 AM

Now the time consuming part..

The surface has to be smoothed out, so time for the trusty fibreglass for deep holes and filler for the smaller ones..

When filling, it is better to do 5 thin coats than 1 thick coat that you spend weeks sanding down.

Try get each layer as smooth as possible using only a small amount of filler at a a time.

Sand between each layer and it makes life much easier.

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#12 cooper_shaz

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Posted 18 October 2005 - 09:41 AM

for the small parts you cant get the sander into, sand by hand or use a dremmel or similar multi tool.

How smooth you make this depends on your chosen finish

If you want to paint it, then you need it totally smooth,
if you are going to cover in fabric then get it as smooth as poss.
A very thin layer of foam covering the lot before trimming hides minor imperfections.

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#13 cooper_shaz

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Posted 18 October 2005 - 09:43 AM

Smoothed and ready to trim.

Using a material called leatherette about 5 quid a sq meter and you can get it almost any colour you want.

Looks like leather and is flexible..

Trimming it is a seperate subject.. but loads of swearing, spray glue and a hairdryer and essential tools.!!

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  • Attached File  pic9.jpg   20.46K   73 downloads


#14 cooper_shaz

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Posted 18 October 2005 - 09:47 AM

If you are trimming work small areas at a time..

Lay the fabric over the whole enclosure and hold it slightly loose

Work from one corner

use cans of spray glue and spray the surface of the enclosure 6 inches at a time...
warm the fabric (helps it stretch) and apply it to the surface..

If will stretch into the curves etc..
take you time here!! if will pay off ..!!

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#15 cooper_shaz

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Posted 18 October 2005 - 09:49 AM

might be an idea to start with something smaller like door pods..

pics below

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  • Attached File  pod1.jpg   16.51K   19 downloads





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