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Volvo S60 build resurrected! Old School!
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<blockquote data-quote="americannight" data-source="post: 8033092" data-attributes="member: 624648"><p>It may not look like it but I put a full day into the enclosure. This was spent filling in pits with body filler, sanding, more body filler, and sanding some more, finally with an extra fine sanding sponge. I also filled in the gap between the two chambers with great stuff foam. The gap was caused because the fleece around the speaker rings did not touch the center divider. I could use some advice here, having never used great stuff on a speaker enclosure before. My original idea was to use the great stuff to fill the gap and then paint over it with resin. Do you guys think the resin is necessary or is the great stuff by itself pretty air tight? The can says the stuff is air tight. Heck, it seems to have filled the gap really well. As you can see in this picture, I went a bit overboard. But if you guys think it's worth the extra effort, I'll paint it with resin to add more barrier.</p><p></p><p><img src="http://www.theamericannight.com/images/s60system27.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I also have done a test fit with the woofers. This was to make extra sure they fit right before getting to the finishing stage. Once the back is on this enclosure it will be harder to make adjustments later. I also wanted to make sure the bolts threaded straight on to the T-nuts. This was a concern. With the baffle being 2" thick and I do not have a drill press. I had to do my best to make the holes perpendicular with the wood with just a hand drill. I burned about 2 hours today driving around to different hardware stores looking for 10-32 3" bolts. I thought 2" would do it but those would not make it all the way to the T nut threads by the time the thickness of the speaker gasket was factored in. 3" bolts with the fine thread were very hard to find but finally did locate them at Home Depot of all places. Struck out at Ace, Lowes, Fred Meyer, and finally hit pay dirt at Home Depot. Only two of the T nuts seemed a bit out of place but once I whacked on them with a hammer a couple times, I got them to marry with the bolt. Once all the bolts were lined up with the T nuts, I tightened them by hand to give the T nut a final sink into the wood so the bolts should go right on during the final assembly.</p><p></p><p><img src="http://www.theamericannight.com/images/s60system28.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Lastly, I drew the cut holes for the precision ports. It's pretty neat they make these so the diameter of the inside flare serves as a template for the hole you need to cut for the outside flare. That makes it pretty idiot-proof. Once the holes are cut, I'm going to route around them about 1/8" deep so the outside flare will be countersunk and flush with the top of the enclosure. With the added thickness that the fiberglass added to the top of the box, it is now a very tight fit getting it into the trunk. Countersinking the port flange will ensure that it still fits through the trunk opening.</p><p></p><p><img src="http://www.theamericannight.com/images/s60system26.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p></blockquote><p></p>
[QUOTE="americannight, post: 8033092, member: 624648"] It may not look like it but I put a full day into the enclosure. This was spent filling in pits with body filler, sanding, more body filler, and sanding some more, finally with an extra fine sanding sponge. I also filled in the gap between the two chambers with great stuff foam. The gap was caused because the fleece around the speaker rings did not touch the center divider. I could use some advice here, having never used great stuff on a speaker enclosure before. My original idea was to use the great stuff to fill the gap and then paint over it with resin. Do you guys think the resin is necessary or is the great stuff by itself pretty air tight? The can says the stuff is air tight. Heck, it seems to have filled the gap really well. As you can see in this picture, I went a bit overboard. But if you guys think it's worth the extra effort, I'll paint it with resin to add more barrier. [IMG]http://www.theamericannight.com/images/s60system27.jpg[/IMG] I also have done a test fit with the woofers. This was to make extra sure they fit right before getting to the finishing stage. Once the back is on this enclosure it will be harder to make adjustments later. I also wanted to make sure the bolts threaded straight on to the T-nuts. This was a concern. With the baffle being 2" thick and I do not have a drill press. I had to do my best to make the holes perpendicular with the wood with just a hand drill. I burned about 2 hours today driving around to different hardware stores looking for 10-32 3" bolts. I thought 2" would do it but those would not make it all the way to the T nut threads by the time the thickness of the speaker gasket was factored in. 3" bolts with the fine thread were very hard to find but finally did locate them at Home Depot of all places. Struck out at Ace, Lowes, Fred Meyer, and finally hit pay dirt at Home Depot. Only two of the T nuts seemed a bit out of place but once I whacked on them with a hammer a couple times, I got them to marry with the bolt. Once all the bolts were lined up with the T nuts, I tightened them by hand to give the T nut a final sink into the wood so the bolts should go right on during the final assembly. [IMG]http://www.theamericannight.com/images/s60system28.jpg[/IMG] Lastly, I drew the cut holes for the precision ports. It's pretty neat they make these so the diameter of the inside flare serves as a template for the hole you need to cut for the outside flare. That makes it pretty idiot-proof. Once the holes are cut, I'm going to route around them about 1/8" deep so the outside flare will be countersunk and flush with the top of the enclosure. With the added thickness that the fiberglass added to the top of the box, it is now a very tight fit getting it into the trunk. Countersinking the port flange will ensure that it still fits through the trunk opening. [IMG]http://www.theamericannight.com/images/s60system26.jpg[/IMG] [/QUOTE]
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