Revscene’s own sound guru Orgasm_Donor has given us a small step-by-step how-to on how he made his fibreglass door pods in his 350Z. Read more on just one of the techniques that he has picked up throughout the years but he finds it to be the quickest and most effective. We’ll let him explain further.
The speakers that I have chosen for this fabrication are the DD-A series German components. The speaker does not require a lot of space so I decided on a sealed enclosure as opposed to using the entire door as the baffle.
For starters I removed the door panel and I popped the speaker grille out. I found a piece of 7″ diameter PVC pipe that fit perfectly in the hole where my grille used to be.
If you want greater detail in some of these pictures, click on them for larger versions.
I made a back baffle out of 1/4″ ABS and glued it to the back of the pipe as shown. I cut the pipe to follow the contour of the face of the door panelso it fit flush. I then taped the bejesus out of the area to be fibreglassed.
Here I am fibreglassing the outside of the door panel. I am using 1.5 oz. matting and marine grade fibreglass resin. I use small strips of matting so its easy to get into the edges and corners. Please do not taste the resin – its terrible!
After about 2-3 layers of glass, I let it cure and removed it from the door panel. Here is a test fit after I trimmed the edge
Using a quality router and a circle jig, I made two nice speaker rings out of 1/2″ MDF. This is what the speakers will be mounted to.
I hot glued on some little stilts here so I could position the baffles onto the backplate I just made
And here we are with the baffle in place and spaced nicely on the plate. I spent quite a bit of time positioning the midbass so it aimed up towards my head without getting in the way of my knee or seat.
And here is my new mid bass driver positioned in the baffle for testing purposes.
And test fitted on my door.
Here I am stretching some fleece around the baffle and back plate to create a nice smooth surface. I use a quality upholstery stapler and 1/4″ staples to attach the fleece. In some cases I will use some CA glue to adhere difficult edges.
This is getting nice and close to what I want! Stretched and stapled/glued. Ready for more fibreglass resin!
One down…one to go
Now I resin coat the fleece. I don’t bother with the speaker hole area because I’ll be cutting that out later. I usually use two full coats of resin to make it nice and tough. For this project I also added two layers of fibreglass matting to make the pods strong.
After I beef up the pods with fibreglass, I do a skim coat of bondo or body filler. I prefer ‘Icing’ because its light and easy to sand. Now they are really taking shape!
Test fit on the door
I chose to use a high grade vinyl to match my leather seats. The stitching was done by a friend of mine.
Now, I would say that these took me about 15 hours from start to finish. The sound Quality is incredible and my mid bass driver can safely play down to 60 hertz. The reason why I built them this way is so I can remove them and maintain the stock door panel with no problems.