GolfGTIforum.co.uk
General => Car audio => Topic started by: B-chi on 11 October 2010, 17:42
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As with everything I rush and rush to get things done and only half finish everything. The current build is no exception.
After a poor 144.7db peak @ 40Hz and 141.8db average in PD I'm going to take my time and get everything done and finished for the start of the PD season next year.
I've now moved and have a garage so once I've finished the various DIY bits to be done I'm going to plough on with the build. Needless to say updates will be slow.
So the first pics of project 150db.
One 1000mm x 100mm x 15mm block of Ali.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0269.jpg)
Measured up and scribed where the holes are to be drilled
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0270.jpg)
Holes punched ready for drilling
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0271.jpg)
These will be the bus bars for the power cable. Each bus bar is capable of taking 18 runs of 0awg. Tomorrow I'll cut and drill these and mount the negative block on some perspex ready for fitting.
Thats It so far. I told you it would be slow but everything is going to be done properly this time around.
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Can I ask why you didnt use copper? The expense?
http://www.tpub.com/neets/book4/11e.htm
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I acquired this block of Ali at work. I don't have access to the copper store and don't know anyone who can get me in there. So Ali was the next best thing.
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Just a small update.
Although the main bus bars haven't been finished work has begun on the connection blocks from the alts to batteries.
Pos and Neg to fit the double insulated 0awg I'll be running throughouit the engine bay.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0274.jpg)
Thats it. Said it would be small.
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A very special day for me today. Now I wasn't able to help out with this today so unfortunately can't take any credit for it.
Here are the first shots of my new busbars. Both bars are 15mm thick. The holes for the 0awg are 10mm diameter and the grub screws are 6mm tapped with a little grub in.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0284.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0283.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0282.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0281.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0280.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0279.jpg)
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Had a bit of spare time today at work.
Took the Sundown off the passenger side and put the Audiosystem there instead.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0311.jpg)
Speaker cable was already run into the boot so just need to trim it to size.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0308-1.jpg)
Cut the wood for the Sundown to be mounted on the drivers side
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0313.jpg)
Also cut the trim panel to allow the amp to fit in.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0309.jpg)
I'll make a surround for the each amp then fiberglass a nice shape over the whole panel and then trim or paint.
Also cut a board to mount the 4 crossovers on. These will go behind the dash.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0312.jpg)
Won't be able to mount the amps as still need to mdf and expandy foam the rear 3/4 panels.
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wot has happened have u abondened projet 150db :sad: :sad:
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No not abandoned just on hold. I need to get abit of welding done before I can carry on. I've got everything in place ready. It's frustrating not being able to crack on.
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Hurry up get the welding done and get the install back up and running lol I'm looking forward to seeing the build thread
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Just over a week ago it looked like this was going to tbe yet another install I would not complete. A turn of events however has inspired and enabled me to start work on the rebuild so without further adoo bring on the pics.
Pics of the mounting for the crossovers and component amp. I've bonded 18mdf to the outer panel, bonded 18mm mdf to the inner panel, then bonded the inner and outer together with 3x2 timber, then filled the whole 3/4 panel with expandy foam. Solid as a fooking rock now.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0498.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0500.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0496.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0499.jpg)
Have also got my hands on some aluminium box section and 3mm steel to do the roof with.
Not sure how but I seem to have lost one of my crossovers.
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No money for fiberglass just yet so this will be how it stays for a while.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0501.jpg)
I'll make up a frame to go around then fiberglass the frame to the panel, but not just yet.
Latest accomplishment is the roof.
I have, had a sunroof lol. Took everything to do with the sunroof out and off. Gripfilled some mdf to the roof, then screwed and glued some mdf brace across where the roof used to be. Gripfilled mdf to sunroof glass and packed out as necessary, then used a sealant adhesive to seal the sunroof in and voila.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0515.jpg)
Measured up and decided a 2 part roof would be easiest. Only managed to get the last half in but am hoping to finish tomorrow.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0516.jpg)
Used the existing brackets which held the sunroof runners on.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0518.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0519.jpg)
This pic is of the boot end. Bent the metal using screwdrivers, then whacked it in using a mallet.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0520.jpg)
18mm thick, this will be expandy foamed to the actual roof as well then I'll add another sheet of 18mm which will be trimed in whatever I fancy at the time. For the front all the existing bolt holes which held the runners on are going to be used to mount the mdf roof, then the next layer screwed and glued to this one.
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I've finished the first layer of the roof. Not massively impressed with the screwfix expandy foam. Not as solid as I expected. The roof will stay single layer for Pure carma. I want to make sure it's up and running before I start finishing things.
Ordered a new alternator although the guy hasn't been responding so I think I may of been screwed over there but will wait and see.
Also started on the door cards. I've ummed and arghed a fair bit about what to do with these so thought I'd take it bit by bit.
First off I made a rough template to get the bolt holes in the right place.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0525.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0524.jpg)
Then Layed template on the sheet, marked up, cut out and trial installation.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0527.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0526.jpg)
Was hoping to route the speaker holes out but have got the router bit stuck in the router. I think it's f**ked and it's not even mine. Anyone know how to get a stuck router bit out.
Progress is slow but is coming along. Also started on the a pillers but no pics yet.
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I was able to get hold of a working router. A Bosch one, it's awesome. Also just figured out that you can use the slider thing as a circle jig. I needed 74mm and the smallest it went was 78. So I hacksawed a bolt leaving a point on one edge given me 76mm. It's a bit tight on a couple of the mounting holes but should be ok.
I've made a couple of baffles and wasn't happy so went with this.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0530.jpg)
Nice and simple. I've decided I'm not going to keep this door card. This is just for Pure carma on the 7th. I'm not happy with how it lines up so will be redoing one slighlty bigger and straighter to match the lines of the door better.
You'll also notice it looks like I have two different type of speakers. For some reason the two sets of helons are different yellow and different logo.
Decided to start on routing cables.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0532.jpg)
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0533.jpg)
This was a very tight squeeze indeed. Fricking nightmare infact, I was filing for like half an hour and I hate filing. Got them in though. Also figured out that if I remove the middle connecting block on the other side (which is for the speakers) They'll fit easily. The mk3 really was designed with a aftermarket install in mind. I've room down the side channels to run the 6 runs of 4mm2.
I Learnt from previous mistakes so have left plenty of cable to connect to the crossovers. Bought the wrong size crimps. 4.3mm yellows so too big for the crossover terminals. Think I need 3mm.
(http://i369.photobucket.com/albums/oo137/B-chi/Project%20150db/IMG_0534.jpg)
iPhone died so will take more pics probably tomorrow.