[CaptainMorgan]

Nope. I measured how far I'd have the speaker rings out in each seat with my legs in the car, placed at the widest comfortable position. If I try I'll bump it, but it won't bother me normally.

You have to remember, I'm really skinny.

[CaptainMorgan]

If you look at the wide angle shot again you can see what I'm talking about.



In that line of sight you can still see in full view the rubber/plastic spot on the carpet for the drivers left foot to rest, not obstructed by the speaker ring. There isn't any extra room, but I fit.

[2ToneR/T]

dude.....HOLY SHIT!!!!!!!!!! Thats freaking badass!!!!!!! You are gonna be deaf by christmas!! lol

[scarce911]

Deaf from a set of components..lol .. wouldn't that suck?!!

Nice progress.. I appreciate your attention to detail..

[CaptainMorgan]

Ideally I won't lose hearing. I won't push these anywhere even close to their max volume. For really high SQ you needs lots of power/power handling so you don't reach the points near the equipment's limits where distortion levels rise.

The placement and quality of drivers is by far for the purpose of SQ, but if I wanted to show off I could blast some ear drums.

[beeblebrox82]

very badass.

[CaptainMorgan]

Alright, back in action. I've already gotten advice on how to do this differently in the future, but my current methods will all work. It's just a matter of learning the most efficient path towards completing a project.

I wasn't sure so I just went ahead and totally taped up my speaker rings. My plan was just to fill up the whole deal with foam and because I have the big opening in the back remove the foam after I glass this. That'll still work, but essentially most people just put in something like tagboard pieces to keep the foam from going where you don't want it.



Now I took the saw and sander to my giant foam chunks to carve them back down to door pods. This is still a really rough shape with lots of work left to do, but it resembles what I'm going for now. I ended up starting to remove foam from the center of the one pod just to let me get my sander in to a couple spots, and got a bit distracted. Removing that stuff right now isn't really important.



I'm sure I'll get a little bit of work done tomorrow and Friday morning, but I don't expect I'll be doing any glassing until Sunday night at the earliest. I'll be out of town for the weekend for work.

[CaptainMorgan]

Alright guys work and life got in the way for a few days, but I got back to it and have some real progress.

I finished sanding the foam into my shape, blew off the stray foam with the air compressor, and got to glassing. These were a huge pain in terms of shape for glassing, particularly considering how new I am at this. The second one definitely went a lot easier than the first one. I ended up doing thinner strips to make it around the areas that curve in two directions. I also forgot to tape off the speaker rings on the inside the first time, which means I have to sand that back down. Noob mistake.

Here are my fully glassed and cured pods. No hiding my work/mistakes, I've got all angles.















This is just after doing the rough trimming that I did while it was about 2/3 cured. Now it's time for some sanding before I go to the first round of filler. I'm going to sand down the stray fibers on the surface as well as the lines from the overlap of the top layer of mat.

I'll also tear out the foam now. I've got a couple of ideas to make that go pretty easy.

[cdmccul]

Awesome... Moar!

[CaptainMorgan]

Soon. I just did my rough sand job on the outside and carved out pretty much all of the foam. Tomorrow I'm going to pick up some wire wheel dremel bits to strip the remnants and then I can reinforce weak spots. I'm also going to test fit in the car tomorrow to see if I need to sand down any specific spots on the outside to make sure it still clears.

[beeblebrox82]

awesome

[CaptainMorgan]

Here we go.

So in the process of my test fitting after glassing the pods I did end up sanding through enough of the fiberglass in a few spots that it was pretty weak. I cut through in a couple of those spots, carved into the foam, and then used kitty hair to rebuild the sections. It was really just two spots on the drivers pod that really needed this (not clearing the arm rest as easily as I thought). I used the kitty hair to fill in a few other spots that needed larger chunks while I was at it.

In the other areas I thought needed reinforcing I had access to the back after having removed the foam. I added a few layers of glass on both the inside and outside where needed, reinforced seams with a layer of internal glass, and stuffed some more kitty hair into a couple of spots where I wasn't going to realistically be able to add glass. This is all probably overkill, but I build things to be durable.

Then I went ahead and did the full body filler coat. The one pod I did in two parts just because I underestimated how much I'd need when I mixed up the filler. I used rage extreme body filler.

Here is where I'm at now. This is just knocking it down with a rough grit sand paper while it wasn't rock hard (started in green stage and went until happy for now).







Keep in mind these aren't meant to be symmetrical with how they're aimed, but some of that will get evened out in sanding.

Over the weekend it'll be test fitting, sanding, and a little primer to work on sanding to a paintable finish.

[cdmccul]

Now - call me crazy, but I see something a little more soft and fleshy when I see them pods sitting like that. Looks like a nursing bra on top... can't put my finger exactly on what I'd say the bottom picture is specifically....

hahaha

Great looking project, I like the step by step!

[CaptainMorgan]

I didn't even think of that. Nice.

[Scooter-Man]

Ding-Ding-Ding- any updates? The Holidays are here, so it might be a while.