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Old 05-11-2006, 09:33 PM   #1
Audio Integrations
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Talking The Audio Integrations Demo Car Build (Audio) Update 05/19/06

Ok as some of you may know I started a thread "another fiberglass option" a while back showing our subwoofer enclosures ready for the mold process. We're now vendors and the 12 inch 04 - 06 STI / WRX model is in stock and ready to go.

It's in the vendor "for sale" section for more info on it.

My 05 WRX sedan is now going to become my shops "demo" car. Nothing crazy like a lot of shops cars are, pretty straight forward. The cool thing is almost all the installation pieces I will be using in it will be made from fiberglass so it's lightweight, available for sale on our website, and will have a large selection of different materials and colors to choose from. All said and done a person could have a total custom looking install for a fraction of the price.

I thought this would be a good place to show the progress of the build up, as well as get feedback on some of the products we'll be developing along the way. We'll post pics as we move along so you can see some of the work in progress and hopefully use some of the ideas and techniques used for your own system.

Here's the current idea and setup, some of it like the headunit and things may change when I actually get to that part, but for now its:

Headunit - Alpine? - Flush mount with Tein EDFC controller

Front Speakers- Diamond Audio S600s and S440s in the front doors (Hex 6,4,tweet) in custom door pods

Subwoofer - Diamond Audio D6 12D2 - In a Perfect Fit Enclosure

Amplifiers - Diamond Audio D6 300.4 - All channels running doors, no rear speakers and Diamond Audio D6 1000.1 - Running 1 ohm mono to the 12

Wire and Accessories - Phoenix Gold

Alarm - Clifford Avant Guard 5 Remote Start

Damping Materials - Cascade Audio Engineering

Pretty simple setup but it will sound amazing when done! We'll also be showing the other mods we do to the car as well. So I know none of you have seen a stock 05 WRX before so here it is in all it's glory.

The Perfect Fit Enclosure may get swapped out for a custom color matched version in the future, but for now I'm going to be rockin' the carpet.





AudioIntegrations.net[/b]
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Last edited by Audio Integrations; 05-19-2006 at 07:55 PM.
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Old 05-19-2006, 07:56 PM   #2
Audio Integrations
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*UPDATE* 05/19
Amp Rack

Here's a couple of shots of the sedan amp rack and the beginning of the mold. It will sit vertically behind the rear seats, mount with a couple of brackets, and have trim panels that trim it out to the car. We have to build up the mold nice and thick before we can even think about demolding it.



The original (in yellow) with flanges added for the mold process.



Tooling gel coat applied.



The first couple of layers of fiberglass mat laid down.
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Old 05-19-2006, 09:15 PM   #3
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This should get interesting.... more pics!!
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Old 05-20-2006, 05:19 PM   #4
Rody93
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This is going to look really nice! That system is gonna be bumpin!
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Old 05-20-2006, 05:38 PM   #5
ControlFreak
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Ahhh very cool can't wait to see the updated pics!
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Old 05-21-2006, 03:50 AM   #6
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looking nice....waiting for more pics
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Old 05-21-2006, 11:56 AM   #7
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yes more pics. dont really see where it is going.
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Old 05-21-2006, 07:40 PM   #8
BlueThang
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Subscribed
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Old 05-21-2006, 07:44 PM   #9
djerickd
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cool!!
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Old 05-21-2006, 09:54 PM   #10
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10 in. man, I need a 10.

Also whats the Volume of the 12?
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Old 05-22-2006, 02:15 AM   #11
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it is going to be interesting! but pics are always needed for this type of discussion.
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Old 05-22-2006, 07:33 AM   #12
jbruno
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Subscribe...
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Old 05-22-2006, 02:34 PM   #13
Audio Integrations
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Update 5/22

We added another 1/4 inch of mat to the first layers and let it cure. Then we added a flat piece of wood in the bottom and the frame up top to keep everything flat and straight. After a couple more layers of mat we will pull it all apart.




Here's the begining of the door pods. I will have a 6, 4, and tweet set up in my door but it will also work for just a 6 and tweet.

















Next we'll add foam to the door panels and grind/sand them to get the desired shape as well as pull our amp rack mold apart.
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Old 05-22-2006, 02:54 PM   #14
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Spectacular photos and work guys! Really great stuff, please keep posting it. I have some questions about the "door pods" you are making.

1)Does the OEM parts remain unmolested? or will you be cutting through to get more depth for the woofer and solidly mounting with epoxy/screws?

2)What do you think the chances are of matching the material on the armrest above?

3)Would it be possible to make a smaller one that retained the pocket access that provided room for a speaker and tweeter only?

Again, great work, and I'm going to follow this thread with much interest.
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Old 05-22-2006, 03:41 PM   #15
Audio Integrations
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Quote:
Originally Posted by LastResort
Spectacular photos and work guys! Really great stuff, please keep posting it. I have some questions about the "door pods" you are making.

1)Does the OEM parts remain unmolested? or will you be cutting through to get more depth for the woofer and solidly mounting with epoxy/screws?

2)What do you think the chances are of matching the material on the armrest above?

3)Would it be possible to make a smaller one that retained the pocket access that provided room for a speaker and tweeter only?

Again, great work, and I'm going to follow this thread with much interest.
Thanks!!

One of the main reasons we're making the door pod is because you can't fit a real nice speaker behind the door panel without it either hitting the window and track or playing into the back of the plastic door panel. A lot of times people don't realize if they do get a larger speaker to fit behind the panel it usually hits the backside of the panel when it's playing at louder volumes. Over time it get's it's butt kick and starts to sound like crap.

You also lose some sound playing behind the door panel. Some of the sound never makes it out from behind the panel and to your ear, it spends it's time reflecting between the metal and plastic door panel. It is in my experience that all speakers will sound better if thier front mounted with nothing between you and the speaker. (except some lightweight grill material)

We positioned the 6 so you only have to cut the circle in the factory door panel and you can load any set of seperates in your WRX. You will have to cut to get a 4 in but a tweet won't be a problem. So yes a little molesting will be needed.

We haven't been able to locate that exact same material used in the upper part of the door yet but we're still looking.

We want to come up with a good bolt/nut combo for mounting to the actual door panel. They will be lightweight since they are fiberglass so you don't need too much, but whatever we do it will be a strong mount.

And yes we will look into building a smaller version for just a 6 and maybe a tweet. It's hard since the pocket is right next to where the 6 needs to be so making something that looks like it's suppose to be there may be a little tricky.

Thanks agian!! - Todd
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Old 05-22-2006, 05:31 PM   #16
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I can start another thread if you want, but while we are still talking about the door cards , I had this in mind:


The red areas would be "deleted" from the pod, and the green dot was a rough location for the tweeter. I'd like to get it rotated forward more, but I'm not sure if that would interfere with the dash. I think this would leave plenty of space to the door pocket, and still provide the additional mounting depth.
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Old 05-23-2006, 12:53 PM   #17
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very nice 'glass work
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Old 05-23-2006, 10:36 PM   #18
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What are you guys using for matting and resin? It looks smooth. Chop sprayer?


Beautiful work.

Matt
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Old 05-24-2006, 12:02 AM   #19
Audio Integrations
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Quote:
Originally Posted by audio1der
What are you guys using for matting and resin? It looks smooth. Chop sprayer?


Beautiful work.

Matt
Thanks!

It's just a general purpose polyester laminating resin and good old hand laid 1 and 1/2 oz. mat. You just got to work all the air out and take your time. You need to make sure every layer gets laid down flat with no little fibers sticking up, or the next layer won't lay flat and you'll get air pockets.

Good times with fiberglass, I've been playing with the stuff for too long now!
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Old 05-24-2006, 12:08 AM   #20
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Any particular reason you're building the door pod outward rather than trying to keep it more flush? Nice work btw.....
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Old 05-24-2006, 02:55 AM   #21
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wow nice! keep us updated.
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Old 05-24-2006, 08:07 AM   #22
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Quote:
Originally Posted by Audio Integrations
Thanks!

It's just a general purpose polyester laminating resin and good old hand laid 1 and 1/2 oz. mat. You just got to work all the air out and take your time. You need to make sure every layer gets laid down flat with no little fibers sticking up, or the next layer won't lay flat and you'll get air pockets.

Good times with fiberglass, I've been playing with the stuff for too long now!
Do you use a roller or just a brush (sorry just picking some brain Im an installer too so just seeing what other people do )

Im actually in the middle of a big FG box for some T1s in a Ram.
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Old 05-24-2006, 12:08 PM   #23
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This makes me glad my speakers are in the stock locations!

Man that's a lot of work. Be proud of yourselves.
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Old 05-29-2006, 10:05 PM   #24
Audio Integrations
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*UPDATE*

It's been a long weekend and we found a bit of time to udate. Heres some pics of the amp racks progress. First we pulled it from the mold and began the task of wet sanding the mold. Theres still some work to do on the mold before we can pull good parts, but we pulled a quick part for developing brackets and flush trim. The outer flush part will be wrapped in the matching carpet, and the inner ring will be available in all the same materials as the Perfect Fit Enclosures.



Quick prototype part being made




Test fitting trim piece








All pieces with carpet and vinyl


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Old 05-29-2006, 10:14 PM   #25
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I just can't say this enough, you do awesome work!
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