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View Full Version : How to: Fiberglass Door Pods ( Panels ) Complete Video Tutorial with CAF



mklett33
08-28-2013, 05:15 PM
http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/Intro_zps2e7dc162.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/Intro_zps2e7dc162.jpg.html)

In this tutorial write up we will be covering how to create some awesome door panel pods that will add a custom look to your install, allow you to integrate multiple speakers into a door panel, and allow you to control the mounting position of the speakers. Note that while these are in fact door “pods” that are not actually permanently bonded are made as part of the door panel itself, there are many techniques within that could be used if you were in fact planning on creating door “panels” from scratch. Let’s begin!

Note: All videos below are within this playlist on YouTube: Fiberglass Door Panels Pods - Video Step 1 Woodwork Templates CarAudioFabrication - YouTube (http://www.youtube.com/watch?v=MXgq4dhr484&list=SPmybwiwzi3MUhb7PJiTb7DwHOOzB9RcKH&index=1)

Step 1: Woodwork and Templates:


http://www.youtube.com/watch?v=MXgq4dhr484

In order to have a good foundation for our door pods we want to make awesome speaker rings. The video above covers many of the details needed. Take your time with this step as clean woodwork is essential to having a good foundation to create the door pods.

Tools needed:
Router
Jig Saw
Jasper Circle Jig
Flush Trim Bit
Rabbeting Bit
Foam Tape
LTP
Stapler and Staples

Upon completion you should have great looking speaker templates that are prepped for molding into the panel.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130602_0013_zps487ead37.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130602_0013_zps487ead37.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130602_0014_zps99151b6f.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130602_0014_zps99151b6f.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130817_0039_zps55e6dcb6.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130817_0039_zps55e6dcb6.jpg.html)

Step 2: Reverse Mounting Speakers:


http://www.youtube.com/watch?v=LJNf3fYrjNI

This step is not essential in terms of design, but it is important to have a plan for exactly how the speakers will mount. The last thing we want is to make these amazing door panels and use wood screws to secure the speakers that will become loose with time. Take a look at the fasteners we used here instead.

Tools Needed:
Drill and Bits
Marker

When complete your speakers will be ready to mount securely to your pods.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130608_0021_zpsbf1c4ad7.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130608_0021_zpsbf1c4ad7.jpg.html)

mklett33
08-28-2013, 05:18 PM
Step 3: Molding the Door Panel Shape:


http://www.youtube.com/watch?v=LQoNDoOyILU

With a foundation for our speakers we now need a foundation for everything to mount too. In this step we mold the shape of the door panel to use it as the back side of the door pod.

Tools Needed:
Resin
Mixing Cup
Mixing Stick
Pigment
Chip Brushes
Chop Mat
Painters Tape

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130601_0008_zps05d46b2e.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130601_0008_zps05d46b2e.jpg.html)

With a complete foundation and mold of the door panel we are ready for the next step:

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130601_0009_zps73b62061.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130601_0009_zps73b62061.jpg.html)

Step 4: Forming the Pod Shape:


http://www.youtube.com/watch?v=XL3Mm7KAvls

We will use similar tools as step 3 to create the actual shape of the pod. The only additional items needed here are glue, and grill fabric.

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130713_0022_zpsfd98514b.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130713_0022_zpsfd98514b.jpg.html)

With the shape complete, it’s time to get things smooth and prepped for paint or vinyl.

Step 5: Body Filler Smoothing:


http://www.youtube.com/watch?v=G2ClU3psoM0

We will use body filler to smooth the panel. Duraglass is a high build filler that adds a small amount of strength but will not crack.

Tools Needed:
Spreaders
Rage Gold
Duraglass
With the panels smooth we are nearing completion of the panels!

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130817_0051_zpseb5ed917.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130817_0051_zpseb5ed917.jpg.html)

mklett33
08-28-2013, 05:18 PM
Step 6: Finishing with Vinyl and Suede


http://www.youtube.com/watch?v=qIT0yCQ89Ko

Painting is a whole other tutorial, in this case we will be using vinyl and suede to finalize things. Take your time here and use the skills shown in the video for some tricks to avoid wrinkles.

Tools Needed:
Vinyl
Suede
Wax Paper
Contact Glue
Knife
Heat Gun
Sunshine

The panels are almost done!

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130818_0056_zps657209be.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130818_0056_zps657209be.jpg.html)

Completion:

With the mounting of your speakers and securing the door pods to the door panels you are done! Enjoy these pictures!

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130821_0068_zpsaffb6237.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130821_0068_zpsaffb6237.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130824_0070_zpsd53cf31b.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130824_0070_zpsd53cf31b.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130824_0073_zps507976e1.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130824_0073_zps507976e1.jpg.html)

http://i1342.photobucket.com/albums/o768/caraudiofabrication/Door%20Pods%20Tutorial/DoorPods_20130824_0071_zpsaa14e983.jpg (http://s1342.photobucket.com/user/caraudiofabrication/media/Door%20Pods%20Tutorial/DoorPods_20130824_0071_zpsaa14e983.jpg.html)

I hope you all enjoyed this tutorial, I had a lot of fun making these videos and I hope they help you learn a thing or two! If you have a YouTube account I would love to have you as a subscriber so that as I continue to make videos you can see them! Thanks for reading! 

Mark

mklett33
08-29-2013, 02:16 PM
Lack of comments makes me :crying:

Lowlacs
08-29-2013, 02:26 PM
I loved the tutorial. I have u on saved youtube and I must say uve givin me the inspiration to build pods for my same chevy doors although I will stayin inside the original speaker placement recessed area. Thanks for what u do man!

mklett33
08-31-2013, 03:33 PM
I loved the tutorial. I have u on saved youtube and I must say uve givin me the inspiration to build pods for my same chevy doors although I will stayin inside the original speaker placement recessed area. Thanks for what u do man!

No problem, thank you for posting!

mklett33
09-02-2013, 07:01 PM
Mods: Please consider moving to reference database! I don't see it getting much attention here as most come to this section for box design.

mklett33
09-06-2013, 02:20 PM
Mods: Please consider moving to reference database! I don't see it getting much attention here as most come to this section for box design.

See above!

Silver-N-Black
09-06-2013, 02:39 PM
Might we do my doors and run with this idea.

mklett33
09-10-2013, 02:57 PM
Might we do my doors and run with this idea.


Nice! If you have any questions along the way let me know.

04murdalanche
09-10-2013, 03:03 PM
love this man,i build doors for people all the time, picked up some nice knowledge watching and reading the vids and tutorials, thank you for posting this.

Jeffdachef
09-11-2013, 06:10 AM
http://www.youtube.com/watch?v=Hq9u9d2sjwE

This is one of your more professional videos.

squalor
09-12-2013, 02:28 PM
I watched them. Thank you for your effort.
Is there any sound advantage to reverse mounting ? Any sound advantage to the 45* bevel (horn) around the woofers and tweeters ? How does it sound ?
It's helpful that you tell us the products that you use. When I saw you mixing bondo, I thought, "that's taking too long, it's going to harden on him", but the Rage Gold did not.
Could you make a video teaching how to make grills ? In particular, metal mesh grills in odd shapes ? Could you look at my thread in this forum and suggest ways I could give my kick panels a nicer apperance ?

KTMrida4life
09-18-2013, 04:47 AM
I somehow stumbled across this thread and figured this post was from years ago then saw the post date of only 2 weeks ago!

Thanks for the awesome video, Im sure it will help me with my first fiberglass project

mklett33
10-12-2013, 04:09 PM
I somehow stumbled across this thread and figured this post was from years ago then saw the post date of only 2 weeks ago!

Thanks for the awesome video, Im sure it will help me with my first fiberglass project

Glad to hear it and I am glad you liked it, I am hoping a mod will notice it and consider moving to the "reference database" Section. I spent a lot of time with the videos and stuff and would like people to learn this, hate to see it get burried under box design requests! :p:

mklett33
11-20-2013, 02:34 PM
Im thinking about re wrapping these to a different color scheme, any thoughts?

vibe
11-20-2013, 03:36 PM
thanks for helping us all out. i know i will benefit from these videos!!