project 150db

[B-chi]

No money for fiberglass just yet so this will be how it stays for a while.



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.



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.



Used the existing brackets which held the sunroof runners on.





This pic is of the boot end. Bent the metal using screwdrivers, then whacked it in using a mallet.



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.

[B-chi]

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.




Then Layed template on the sheet, marked up, cut out and trial installation.




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.

[B-chi]

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.



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.




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.



iPhone died so will take more pics probably tomorrow.