Phase 1 of my trunk build - DodgeIntrepid.Net Forums - Dodge Intrepid, Concorde, 300m and Eagle Vision chat
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post #1 of 40 (permalink) Old 08-29-2010, 06:50 PM Thread Starter
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Phase 1 of my trunk build

So I've talked a bit here and there about my plans for a couple of years, but here is what I'm working on.

I am taking 3/4" thick MDF pieces and cutting them to fit into flat metal spots on the floor of the trunk, and then I am mounting T nuts from the bottom into those pieces (countersunk so they sit below the surface of the MDF.
I got a big pack of really nice 6 prong T nuts that I'm using.


Then I am sanding the floor of the trunk and using epoxy to adhere these to the floor of the trunk. This gives me mounting points that have real metal threads and I never need to drill into the sheet metal of the car. Peace of mind as well as extremely functional. The other advantage to this plan is that there is 3/4" below the mounting boards that will go in for wires to be routed underneath. Eventually you won't see any wires other than plugging into the equipment.

So onto the pictures.

Here is the bare trunk with the first round of mounting points set and ready to use. The bolts are sitting in them so that I can use them to mark their location on the board that the equipment will be mounted to.





Here is the front and back of the first board going in. On the one side you can see the pencil marks that I used to outline the bolt heads, then I drilled through the center from the bottom of the board. With the board in place I was only able to reach in and half outline the bolts, but that was enough to then finish the outline out of the car. The other side you can see I countersunk the holes so those bolts will lay flush and everything can be mounted over them.





Then here is me sitting the 3 amps in the trunk approximately where they will go. I am orienting them this way so that I can keep all the power and all the signal wires safely away from each other. The empty area to the right in the picture is for all the power to go.



Then I rough built my battery box. It is screwed together for now so that I can take it apart later to carpet it or finish it however I desire. I'll sand the edges and all that to make it look nice then. I have to put a piece over the tap as a hold down strap as well, but I can get to that later, its really secure for now.

The battery box is screwed down and good to go right where it is.




Now that I've shown my progress, I'll lay out the grand scheme. The entire trunk will be covered by this layer of MDF, all the way back. I'll build some hinges in so that the whole thing swings up for spare tire access and then I have some other hardware to use for keeping it all secure when it is sitting in the trunk (more parts-express goodies). I have a sub box half finished already that is build to fit behind the passenger side wheel well and hold 2 JL 8W0s. In the meantime my neighbor gave me some shoddy little box he was going to throw out and I might toss the two subs in there temporarily while I keep working, but we'll see if I bother with that. The rest of the trunk space that I'll have to use will go towards holding all the computer equipment that will someday be running my car entertainment system. That is still a little ways away, but I'm always building for the future. Once all this stuff is in then the computer will actually be pretty easy to install.

After I get that all squared away I'll build the false floor for the trunk. All of that will be buried underneath another floor that will return the trunk to being functional. It will have large plexiglass windows to show off the equipment, and with that will go some lighting inside there. With the final "finishing" phase of the project I'll also build in walls to separate certain equipment that will have grounded metal shielding, carpet or otherwise cover any bare wood, and whatever other dress up I end up going with. There will definitely be a layer of 1/8" hardboard that goes on top of this MDF that will be what gets the final finish, allowing me to go all the way to the trunk walls to meet up with the factory trunk carpet, the sides of which will all go back in and tuck underneath the false floor to give it all a good look. There will also be a pretty advanced cooling system build in with fans, ducting, and baffles.

For now I'm just trying to get everything strapped down and all my speakers powered. I also want to get all the wiring shortened up and the correct lengths to eliminate any excess in the system, especially with the power wiring.



My car won't ever be done because I'm insane. That is all.
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post #2 of 40 (permalink) Old 08-29-2010, 06:58 PM
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God damn I LOVE your thoroughness! I need to stop by and look at what your doing. I'll do that in a couple weeks when this quarter is over.


Good work as always Dan!
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post #3 of 40 (permalink) Old 08-29-2010, 07:09 PM Thread Starter
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God damn I LOVE your thoroughness! I need to stop by and look at what your doing. I'll do that in a couple weeks when this quarter is over.


Good work as always Dan!
Well thank you Dave. It makes things take a long time, but the final product is always worth it. One of these days the car will all come together, and I'll just be so happy.

I'm headed out to see how much more I can get done tonight, I have a few things I want to tidy up on that board and them I'm going to screw down all those amps and start hooking them up. If I get that far I'll be plenty happy for today. I'm also going to mount my Audiocontrol Matrix now to help clean up the crappy 2V signals from the HU before going into the amps. Its real purpose is to take a sound card's output and boost it up for use with amps, but it will help plenty at this stage as well.



My car won't ever be done because I'm insane. That is all.
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post #4 of 40 (permalink) Old 08-29-2010, 07:09 PM
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that is pretty cool!
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post #5 of 40 (permalink) Old 08-29-2010, 07:11 PM
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Dan, if it was anybody but you I would have been surprised to see a person take this so far, but for you I'm just not lol. As always, I'm looking forward to the end product!
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post #6 of 40 (permalink) Old 08-29-2010, 07:13 PM Thread Starter
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Dan, if it was anybody but you I would have been surprised to see a person take this so far, but for you I'm just not lol. As always, I'm looking forward to the end product!
I take that as a huge compliment Steph, thanks .

I like the mad scientist rep.

I'm mostly looking forward to having bass very soon. I just can't take it not having subs anymore. My whole system will jump up a huge notch once I can fill out the whole frequency range and tune the other speakers accordingly.
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post #7 of 40 (permalink) Old 08-29-2010, 07:20 PM
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I take that as a huge compliment Steph, thanks .

I like the mad scientist rep.

I'm mostly looking forward to having bass very soon. I just can't take it not having subs anymore. My whole system will jump up a huge notch once I can fill out the whole frequency range and tune the other speakers accordingly.
No problem!

I don't blame you about the bass, I go nuts when I have to take my subs out, just doesn't sound the same at all. I'm going to be buying a nice bunch of wires for the M soon and setting up the system in there similar to what's in the trep but much cleaner with better wiring, hopefully better sound in the end, so expect a PM sometime soon!
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post #8 of 40 (permalink) Old 08-29-2010, 07:22 PM
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I like the mad scientist rep.
Yep....





lol
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post #9 of 40 (permalink) Old 08-29-2010, 07:50 PM
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Damn Dan...you're going all out! Great job so far though. Very interesting.
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post #10 of 40 (permalink) Old 08-29-2010, 07:50 PM
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Very cool! I like the idea of the false floor. I also can't believe we both have that same Pioneer Amp lol.
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post #11 of 40 (permalink) Old 08-29-2010, 08:00 PM Thread Starter
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Very cool! I like the idea of the false floor. I also can't believe we both have that same Pioneer Amp lol.
That is my sub amp. Its rms power is perfect for the subs I have and for that purpose its nice and cheap for now. Some day I'll upgrade all the amps to higher end stuff, but that is not happening until I get everything else worked out. With this floor plan it'll be easy to swap out amps too.
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post #12 of 40 (permalink) Old 08-29-2010, 09:14 PM
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Nice build can't wait 2 see the rest.
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post #13 of 40 (permalink) Old 08-29-2010, 09:53 PM Thread Starter
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Another little nuance of the plan, I am going to eventually make the spare tire well dressed up nice even hidden underneath everything. When I have my powdercoated charger rims down the road I'll make it so when I show off the setup I can show the cool hinge setup and reveal a sweet rim underneath.
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post #14 of 40 (permalink) Old 08-29-2010, 10:07 PM
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Looks good!
Casual observations:
Hope epoxy is enough to hold. How long was the set time?
Curious how the rear seat will fit in. Looks like it will be close.
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post #15 of 40 (permalink) Old 08-29-2010, 11:34 PM Thread Starter
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Looks good!
Casual observations:
Hope epoxy is enough to hold. How long was the set time?
Curious how the rear seat will fit in. Looks like it will be close.
I measured, but I am concerned that I may be off by less than an 1/8" of an inch on how close the board comes to the seat. The board will come out again though before I put the seats back to get wiring holes drilled and at that time I will trim the front edge if necessary. I want it to be really close on purpose, and a test fit will definitely be in order to make sure I didn't push it too close. I'll wait on that until I get everything squared away a bit more, but I'm actually close to that stage. I mounted all three amps, now I just need to figure out the smaller things - Audiocontrol, crossovers, power distribution blocks, and circuit breaker. Then I get to wire up the other two amps, and I'll wait to trim the wires until after its all fished through the holes in the board.

Doug the Epoxy is a concern of mine as well, but they seemed to hold really strong before I put the whole setup in. I really lathered it on and every piece was put under the weight of a cinder block during the curing. I let them all set for at least 6 hours before touching them, and it was over 12 in between the last epoxy and the first screw tightened down. I started doing those Saturday.

What would you think of as a better adhesive for this purpose? I'm trying to bond between paint/mostly smooth metal and MDF. I got some general purpose stuff because of the difference in materials, but now that I think about it perhaps metal specific would be better because pretty much anything will soak into the MDF just fine.

Now I have to take a closer look at exactly how I'm going to do the back half, thats the more complex part because I have to keep in mind I want it to eventually be a folding section.



My car won't ever be done because I'm insane. That is all.
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