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    Icon10 SDS install log on the SSA Mazda

    Please do take a moment to read this topic and not just look at the pictures, as some of the photos will not make sense if you skip over what I try to say. I am few days behind on getting this pictures posted up, but life and all that goes with it has been in the way. Anyway, a MASSIVE thank you goes out to Don at Sound Deadener Showdown - Your Source for Sound Deadening Products and Information. I had initially hoped to use the SDS product line on the little Mazda with Don's guidance, but he went far and away above the call of duty and took 3, yes 3, very long work days out of his schedule to help me along the way. This was an excellent learning experience for me in terms of the physics of how the acoustics effect the car around me. Don was ever patient with my endless questions and wanted to go the extra mile and spend the extra time to make sure we got it right. Not to mention Don's supply of room temperature orange Gatorade that kept us from dehydrating in the process. I will not get into the demise of the sled (Mercedes Brabus 300ce) at this time.

    In this case, physically having Don there explaining and showing me, step by step, section by section of the car, how and why and where to apply the SDS system was priceless! As you will see in the many following pictures, this is much more of a system, and the full effects were staggering. I say system because the CLD, CCF, Butyl Rope and MLV all have a purpose and work together to vastly change the vibrations in the metal and interior parts, along with sound transmission both into and out of the car. Don has figured out a number of very nifty tricks for installing, one most importantly is the fact that every inch of CCF and MLV can be pulled right out of the car, which you will see below in the pictures. We started in the rear hatch floor area, then worked our way forward on the floor up through the firewall, lastly working on the doors and vertical surfaces.

    I have dampened a handful of cars in the past, heck, I nearly covered every inch of the wifey's old Civic with butyl tiles, many sections with multiple layers, but the performance was not like this. Once we were done, I was grinning like a fool, and opening and closing the door in disbelief as to the difference. The level of silence inside the vehicle is really something, almost cocoon like in nature as your ears take a moment to adjust to the change in noise level. In this rare case, I am not the man behind the curtain, I let Don (former large format pro-photographer) photograph the process, so all these photos are credit of the SDS camera.

    As for the audio in the car, disregard that at the moment as it is still a 7 year old fully stock Pioneer system as I have had the Mazda only a few weeks and I am spending much of my non-daddy time on the road or away from somewhere appropriate to install audio. The funny thing is, how much better the stock audio system preforms. We were both taken back for a moment once we had finished up, I joked that I might just leave it stock. (Though I did lay down power, speaker wire, and RCA's under the carpet for the impending install which is another topic). This was a great deal of work, more then I had anticipated, but so worth it. I keep telling Don on the phone the additional benefits I keep finding out, the latest being that my 4 year old son goes to sleep much easier now due to greatly reduced road noise levels.

    Again, and huge Thank You to Don for all the time, answers, assistance and effort that went into this install.

    Details of the install log:

    Vehicle:
    2003 Mazda Protege5 5-speed

    Materials used:
    SDS Closed Cell Foam
    SDS Mass Loaded Vinyl
    SDS Constrained Layer Dampener
    HH-66 Vinyl Adhesive
    Velcro with dual pressure sensitive adhesive

    Tools:
    Silver Sharpie
    Painters Tape
    Large Shears
    Scissors
    At least a gallon of Mineral Spirits
    Denatured Alcohol
    Utility Knife
    Scalpel
    Razor Blades
    Panel Poppers
    Heat Gun
    Scraper
    Stop watch

    Photos:

    1,2: Hatch Floor before start of install:





    3,4: Begin of tear down:





    5,6,7: Removal of some asphalt on hatch floor:











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    Re: SDS install log on the SSA Mazda

    8: Application of CLD tiles on hatch floor:



    9,10,11: Forming, shaping, cutting, planning of MLV on hatch floor:







    12: Formed and removable hatch floor MLV:



    13: CCF underneath MLV layer:



    14,15: Me cutting MLV moving forward on the floor:





    16,17,18,19,20,21: Completed hatch floor (this was the single most time consuming part of the install:












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    Re: SDS install log on the SSA Mazda









    22,23: Start of front floor area (as you can see, much less CLD then expected):





    24: Test fitting spare tire in well:



    25: Continuation of front floor area:



    26: Bad-*** spare tire sub woofer enclosure:










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    Re: SDS install log on the SSA Mazda

    27: More up front, showing some of the obstacles we were dealing with:



    28: Front passenger door pre-tear down:



    29: Torn down inner door:



    30: Side impact beam before the Extruded Butyl Rope (EBR):



    31: Side impact beam after little pieces of Extruded Butyl Rope pushed down between the beam and the outer door skin (this little amount made a very noticeable change in the door resonance, very smart application):



    32: Small strips of plastic to cover the EBR as it stays sticky forever and will pick up dirt and grime:



    33,34,35: Making templates of MLV for the door's:







    36: Little blue Mazda inside the SDS Headquarters install bay:









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    Re: SDS install log on the SSA Mazda

    37: Cut door skin MLV templates:



    38: Interior of rear doors:



    39,40: Test fitting MLV panel to door skin:





    41: Test fitting MLV panel to door:



    42: Test fitting door skin over MLV:



    43: Cut and trimmed MLV panel on door showing nearly complete coverage:



    44,45: Finishing rear doors into the wee-hours of the night (showing CCF on inside of MLV):










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    Re: SDS install log on the SSA Mazda

    46: Rear hatch panel turned over to show the cut and trimmed CCF with the Velcro and their respective windows:



    47: Completed rear hatch inner skin with cut and trimmed CCF and MLV:




    Thank you for looking at the install log, I hope it is informative and eye opening to you as it was to me. I learned a great deal about my new little car, surprising as to all the engineering features and touches that you do not expect in a sporty little econo-box. As linked above, you can get these products from Sound Deadener Showdown - Your Source for Sound Deadening Products and Information. Lastly, a thank you again to Don!





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