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2005 Ford Focus ZX4
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<blockquote data-quote="just call me KeV" data-source="post: 8803819" data-attributes="member: 656095"><p>So I'm back like a vertabrae. I have a few more photos of the progress I have been making on the door panels. I have finished filling and sanding them. I took them out to "320" sandpaper and they are very smooth. It's a good feeling. I could continue working on them but we're entering the area of diminishing returns as far as that goes. If I were to paint them I would keep going but any of the smaller blemishes wont be seen under the suede. </p><p> </p><p> The first couple photos of the baffle and the door panels. The baffle needs much more work as you can see but it's all good in the hood. We were further along on the door panels. I still haven't redrilled those damn holes but I wanted to focus on the doors first.</p><p></p><p>[ATTACH=full]41405[/ATTACH]</p><p></p><p>[ATTACH=full]41406[/ATTACH]</p><p></p><p> So the sanding and filling pics I have posted are legion so let's move onto something a little more interesting. I had no intention on letting the midbass drivers just fire into the door card and then the door cavity itself. The output needs to be directed. Towards that purpose I have started fab on a wood baffle that the speakers will fire directly into. </p><p> To start, I built a simple template out of cardboard to get the general layout. Once I was happy with the initial tracing I cut it out of 1/2" plywood. I cut the bottom a little more than I should which is why I didnt mirror the passenge side. We will do that one a little better. Then I used some self-tappers to attach it to the sheetmetal. Washers will be used under the head of the screws to spread the torque out a little. This plywood is pretty soft. </p><p>[ATTACH=full]41407[/ATTACH]</p><p></p><p>[ATTACH=full]41408[/ATTACH]</p><p></p><p>I still have a few more holes to predrill for the fasteners. There will be around 10 in total. </p><p>[ATTACH=full]41409[/ATTACH]</p><p></p><p> I traced out the holes which looks goofy AF but you get the idea. I realized I didn't need to take all the material out as the speakers aren't that deep and I only need the hole to be a fraction of the drivers Sd to work. </p><p></p><p>[ATTACH=full]41410[/ATTACH]</p><p></p><p> Next step was cutting holes. A middle inner sharpie line was made from the magnets which I traced around. We ended up meeting in the middle not removing too much material saving most strength of the baffle.</p><p></p><p>[ATTACH=full]41411[/ATTACH]</p><p></p><p> So the last two photos are of me prepping the baffle for some reinforced filler. I want it to be as airtight as possible. More wood dowels and hot glue were used. It's really becoming one of my favorite methods of fabrication. </p><p></p><p>[ATTACH=full]41412[/ATTACH]</p><p></p><p>[ATTACH=full]41413[/ATTACH]</p><p></p><p>So after I shape these with some filler I will use some chop matte and resin so seal them. Once that is complete I will wrap the panels and screw them to the door card. Then I will cover them with a layer of deadener, 1/8" neoprene, then use popsicle sticks to create a direct "tunnel" if you will. </p><p>This is as far as I got today. The weather should be nice-ish tomorrow so more work can be done.</p></blockquote><p></p>
[QUOTE="just call me KeV, post: 8803819, member: 656095"] So I'm back like a vertabrae. I have a few more photos of the progress I have been making on the door panels. I have finished filling and sanding them. I took them out to "320" sandpaper and they are very smooth. It's a good feeling. I could continue working on them but we're entering the area of diminishing returns as far as that goes. If I were to paint them I would keep going but any of the smaller blemishes wont be seen under the suede. The first couple photos of the baffle and the door panels. The baffle needs much more work as you can see but it's all good in the hood. We were further along on the door panels. I still haven't redrilled those damn holes but I wanted to focus on the doors first. [ATTACH type="full"]41405[/ATTACH] [ATTACH type="full"]41406[/ATTACH] So the sanding and filling pics I have posted are legion so let's move onto something a little more interesting. I had no intention on letting the midbass drivers just fire into the door card and then the door cavity itself. The output needs to be directed. Towards that purpose I have started fab on a wood baffle that the speakers will fire directly into. To start, I built a simple template out of cardboard to get the general layout. Once I was happy with the initial tracing I cut it out of 1/2" plywood. I cut the bottom a little more than I should which is why I didnt mirror the passenge side. We will do that one a little better. Then I used some self-tappers to attach it to the sheetmetal. Washers will be used under the head of the screws to spread the torque out a little. This plywood is pretty soft. [ATTACH type="full"]41407[/ATTACH] [ATTACH type="full"]41408[/ATTACH] I still have a few more holes to predrill for the fasteners. There will be around 10 in total. [ATTACH type="full"]41409[/ATTACH] I traced out the holes which looks goofy AF but you get the idea. I realized I didn't need to take all the material out as the speakers aren't that deep and I only need the hole to be a fraction of the drivers Sd to work. [ATTACH type="full"]41410[/ATTACH] Next step was cutting holes. A middle inner sharpie line was made from the magnets which I traced around. We ended up meeting in the middle not removing too much material saving most strength of the baffle. [ATTACH type="full"]41411[/ATTACH] So the last two photos are of me prepping the baffle for some reinforced filler. I want it to be as airtight as possible. More wood dowels and hot glue were used. It's really becoming one of my favorite methods of fabrication. [ATTACH type="full"]41412[/ATTACH] [ATTACH type="full"]41413[/ATTACH] So after I shape these with some filler I will use some chop matte and resin so seal them. Once that is complete I will wrap the panels and screw them to the door card. Then I will cover them with a layer of deadener, 1/8" neoprene, then use popsicle sticks to create a direct "tunnel" if you will. This is as far as I got today. The weather should be nice-ish tomorrow so more work can be done. [/QUOTE]
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