2003 Jetta build V4.1 AKA "Violently Expensive"

mat3833

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Hey guys, looks like it's time for the final version of the jetta build. Been working off and on for about 2 years on this, changing stuff, adding stuff, ripping it all out and starting again, etc. The car itself is just about done, suspension and drive train mounts are replaced, front suspension has been changed to Audi TT knuckles and control arms, struts and springs are done, brakes and wheels finished, parts have been collected for a 2.0l stroked engine and beefed up 5 speed 02J transmission, but the main focus is finishing the audio before I start the engine/transmission build. Here is the current setup as of this morning:

Headunit: Kenwood EXcelon Kmm-x704

Front stage: Hertz Mille legend 3-way.
ML1650.3 on midbass
ML700.3 on midrange duty
ML280.3 for the tweeter

Front stage amp: Helix Msix. Channels 1+2 are running the midrange and tweeters off of the Hertz crossover, channels 3+4 and 5+6 are bridged sending power to the ML1650.3.

Substage:
10w6v2 in .8 cubes sealed @ about 600w

Substage amp:
Taramps Smart 3

Entire car has been deadener and isolated, Knuconcepts RCA's and wire throughout, AGM up front on the stock 150a alternator for now.

Here is the plan for the near future:

Front stage will be switched to active with the help of an audison AP F8.9. Midrange and tweeter will stay the same, but Anarchy 704 woofers will be in door pods instead of the ML1650.3's

Mechman 370a alt is going to be in the works, and possibly a bank of yin long.

Here is where the big changes are coming. Here shortly I should be receiving 2 rather large boxes from the land of maple syrup that will be my next substage. I have 4 sheets of 11 ply Birch on order, permission to use the full extent of my credit card, and the use of a table saw. The back seat has been stripped, and it will be the new home for a large enclosure for 2 18" subs.

I started construction on the door pods yesterday, and I'll be posting updates as things come along. In the meantime, here is a short montage of the past few years, audio and otherwise.

Matt
 

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mat3833

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More pictures

Previous front stage was a set of MB Quart QM 218.61Q comps on a Zed Mikro IV. And the substage was a pair of TC sounds TC-1000 15's on the smart 3
 

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mat3833

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ML1650.3 and ML280.3 replaced the Quart comps for a short period.

Temporary pods for the midrange and tweeter. Rush job, just some 3/4 "Birch" ply from my work, drew up a shape in cad and cut a template on the water jet to route out. Quick sand and some paint.
 

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mat3833

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Pulled out the Helix amp and Hertz 6.5's this weekend in preparation for the upgrade. Started shaping foam for the passenger pod but it's alot more difficult than I was expecting so progress is slow and it looks like I need to rethink my pod design.


These showed up Saturday. More details to come later.

IMG_20220402_144609.jpg

Got an email about the Birch being on backorder. Was told they have 7 ply in stock. Looks like I'm on the hunt for some decent wood to use. It's going to be coated in epoxy so I'll probably end up using regular Ply and add extra bracing.

Matt
 
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hispls

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Not many subs use those PA style acordian surrounds.
 

mat3833

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Not many subs use those PA style acordian surrounds.
I only know of 2 models that use it and come in 18" size, I own both. I'm sure that says something about me, lol /shrug
 

mat3833

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These will be shipped out to me tomorrow, hopefully I'll make some actual progress on the door pods tomorrow.

IMG_20220404_225740.jpg

Trying to do some research on crossover points and slope for active setups. Going to start with factory crossover point from midrange to tweeter and bring the high pass on the midrange up to 400hz to try and clean up the sound at higher volumes since the Anarchy can ay up there just fine. Any input on crossover points would be appreciated. Also need to figure out some kind of passive protection for the midrange and tweeter since I will be running active.

Matt
 

crnacnac

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Nice equipment. I'm doing a Full DA Audison system right now in my '04 R32
 

hispls

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I only know of 2 models that use it and come in 18" size, I own both. I'm sure that says something about me, lol /shrug
Pretty sure TC had a 4hp motor "SPL" variant that used them and I'm thinking one of the beehive neo subs did as well (possibly one of the PA drivers?), but I'd have to imagine someone else has used that style surround between now and the 90's CV Stroker.
 

mat3833

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Nice equipment. I'm doing a Full DA Audison system right now in my '04 R32
I have been forbidden from owning a mk4 R32. First thing I would want to do is 1.8t swap it, and that REALLY offends some people. Don't need more people comming after me with torches, haha.

Matt
 
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mat3833

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Pretty sure TC had a 4hp motor "SPL" variant that used them and I'm thinking one of the beehive neo subs did as well (possibly one of the PA drivers?), but I'd have to imagine someone else has used that style surround between now and the 90's CV Stroker.
The 4" beehive did have the same surround as these. It actually used the same top assembly as a whole from what I can tell.

These are TC sounds Pro 5100's. They have the aura Nrt style motors on them. I've still got the 2 beehive motors that I may build into something in the future, but I'm hope I don't desire an upgrade anytime soon.

Matt
 

mat3833

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So small update.

Lost foam fiberglass pods are probably not happening. Shaping the foam and making things fit how I want them too is proving to be way more time and skill than I have available right now. I'm about to start work on a new spacer for the doors that will fit the Anarchys and moving onto the pillars for the midrange and tweeters.

Audison amp arrived Monday. This thing is ******* TINY. It's smaller than a sheet of paper and only about 2" thick. I got the software installed on my laptop and did a little bit of messing with it, setting the amp outputs and crossovers. With it being Easter weekend I don't think I'll have time to work on the amp rack, but who knows.

Protection caps are on the way for the midrange and tweeters, should be here Friday so I can get everything wired into the plugs for the amp.

Ive got measurements for the box size, so I've got some modeling to do to figure out what route I'm going for the enclosure on these 18's. For the time being, it looks like one will be ran in the baffle I already have, or I may make a new baffle to fit them both in the trunk opening.

Oil pan, downpipe gasket, subframe bushings, and brake pads are all here, got new tires on the car Sunday as well. As soon as the maintenance is done and the leaky oil pan is fixed the car will be back on the road and I'll have some more time to fiddle with things at work so progress should speed up a tad.

Matt
 

hispls

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TC sounds Pro 5100's.
I doubt many of those exist. IIRC they had only just been teased when TC went under the first time. Very nice and I'm sure they will be extremely efficient for a 4" coil.
 

mat3833

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I doubt many of those exist. IIRC they had only just been teased when TC went under the first time. Very nice and I'm sure they will be extremely efficient for a 4" coil.
I don't know of many of them. I had to get these from Canada. There is/was a gentleman selling a NIB one that I was going to grab, but I got the amp instead. Here are the specs:

Power handling: 1,000 watts RMS/4,000 watts peak •
VCdia: 4" •
Le: 2.8 mH •
Impedance: 2 ohms per coil x 2 •
Re: 3.02 ohms •
Frequency range: 15 - 150 Hz •
Fs: 26.5 Hz •
SPL: 94.5 dB •
Vas: 8.88 cu. ft. •
Qms: 6.90 •
Qes: 0.25 •
Qts: 0.25 •
Xmax: 31.0 •
BL: 23.8
MMS: 287g

It is hilariously efficient. 94.5db/w on an 18" sub with 2.5" of well controlled peak to peak Xmax and an extremely low Mms.

I'm not a meter guy, I like my music loud, low, and clean. These are my favorite subs I have ever heard.

Matt
 

crnacnac

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I have been forbidden from owning a mk4 R32. First thing I would want to do is 1.8t swap it, and that REALLY offends some people. Don't need more people comming after me with torches, haha.

Matt
I know the feeling. I'm the oddball R owner that adds 500lbs of stereo equipment :)
 
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