Are your fresh speakers very blimp to fit in the foundry cavity? Construct a door speaker panel or Husk.
Instructions
Preliminaries
1. Bunch up the consequent tools and materials: poster board, medium-density fiberboard, masonite, grille cloth, 1/4-inch foam rubber wrapping, vinyl, velcro, cordless drill, window-crank pin-removal part, hook object, pick thing, panel-popping stuff, air or girdle sander, metal-cutting object, jigsaw, scalpel, voodoo marker, pencil, tape degree, adhesive tape, spray glue, information and staple gun.
2. Degree the Profundity of the speaker, the Profundity of the foundry opening in the door and calculate the further Profundity needed to accomodate the latest speaker.
3. Observe the Chauffeur's door panel and bias where you thirst the speaker Husk or panel to animation. Normally it's assign on the backside quarter of the door.
4. Degree the door and the speaker to assemble firm that the stop you've chosen Testament job, and then construct two templates for the Husk outside of the poster board. The early template is the cardinal exact of the Husk and covers the full length of the backside quarter of the door. The moment template is the moment flush of the Husk and covers the universe where the speaker Testament be located.
5. Advantage the speaker and pencil to hint a circle on to the head template in the world where the speaker Testament be located in the Husk, and divide outside the gap.
6. Tape template No. Two over template No. One and tape both templates on to the door panel.
7. Peep all approximately the templates to produce persuaded that there are no obstructions such as the moulding on the doorsill or the dashboard, the window Eccentric person, or any mill mechanisms inside the door such as the locking mechanism. Whether any obstructions are institute, adjust the templates' point to accomodate.
8. Remove the templates, the hardware from the door panel and then the panel itself.
9. Section absent the plastic liner covering the interior of the door with a scalpel.
The holes serve as perforation so that the sound made by the speaker can escape through the cover.23. Use the sander to buff away excess masonite, which may have built up from the drill piercing through the board, until the surface is flat.24.
11. Capitalization the jigsaw to chop gone the patterns, and then operate the speaker to hint a circle on to the smaller board where the speaker Testament be located. Divide elsewhere that circle very.
12. Cause the two boards well-organized, production undeniable that everything aligns properly. Convenience screws To button up the boards cool however don't sink the screws all the course into the meeting.
13. Community the Husk meeting on the door panel and sink the screws into the meeting and door panel.
14. Flip the door panel over and site the purpose of the screws. This Testament serve as a chaperon when you are ready to mount the Husk to the door panel permanently.
15. Mount the door panel back on the door with the Husk in habitat. Lasting the door and peep to make certain that the pod fits properly. You may have to shorten it a fraction of an inch in the front (if so, sand it down until it fits).
16. Remove the door panel and take the pod off the panel.
17.Cut out the portion of the door panel where the speaker will be located, using the pod as a guide.
18. Use a marker to note pieces of metal in the door that appear to obstruct the opening for the speaker, remove the door panel and cut out the marked metal.
19. Take the pod off the door panel and sand it to round off its corners and to give it a rounding slope to the section that will hold the speaker. By the time you finish the sanding, the assembly will look like one piece rather than two.
20. Push the speaker into the hole from the front of the pod to see whether it fits. Use a file to trim the edges of the hole and sand a little bit on the top of the pod near the hole until the speaker fits properly.
21. Trace an outline of the second template to the back of a sheet of masonite and cut out the pattern. This will serve as the speaker grille.
22. Draw a circle on to the back of the masonite representing the location of the speaker and use a unibit drill to chop Ten or Twenty holes in the masonite within the circle.
Constructing the Pod
10. Hint the outlines of the templates on to the medium-density fiberboard.27Cut some vinyl. Spray glue on to the foam on the pod and wrap the vinyl tightly around the pod with about an inch or so of trim wrapping around the edges to the back of the pod. Heat the vinyl with a hot gun while you are applying it so that it will be soft and pliable and capable of being stretched.
Remove the grille, spray glue on it and wrap black grille cloth around it.
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Cut out a piece of 1/4-inch foam rubber padding, spray glue on the pod and wrap the padding loosely around the front section of the pod with some excess trim going around the edges to about One inch or so of the back.
Place the grille over the speaker housing of the pod to check the fit. Sand around the housing to create a good, rounded edge.25.
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Staple the vinyl to the back end of the pod with an air staple gun and trim off excess material with scissors.
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Take the scalpel and cut several straight cuts radiating from a center point into the vinyl and foam that cover the hole for the speaker.
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Push the speaker into the cuts. Secure the speaker to the pod with screws.
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Mount the pod to the door panel. Sink the screws into the back end of the door panel through the same holes that were made when the unfinished pod was mounted to the door panel earlier on in the construction process. Add more screws to guarantee that the pod is secure.
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Place some strips of Velcro along the back edges of the masonite grille cover and along the edges of the pod that houses the speaker. Make sure that the Velcro strips are aligned.
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Mount the masonite to the pod over the speaker.
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Take the door panel and the pod to the car, attach the speaker wires to the speaker terminals and re-place the door panel to the door.
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Take the templates used to make the pod for the driver's door and flip them over and trace the patterns on to the fiberboard and make the pod for the passenger door as described.
