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DIY: Custom speaker pods and tweeter mounts

Old 03-Nov-2008, 09:29 AM
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DIY: Custom speaker pods and tweeter mounts

Hey guys,

Did this back in august and thought i'd post it on here. enjoy!

This is my first attempt at making something like this, so the outcome wasn't the greatest but considering the circumstances, I'm still pleased with the way it turned out.

First I had to take out the a-pillars








Then I had to make a mold of them for the tweeter pods:









I started making the mold using fiberglass. I just followed the instructions by mixing the hardener and resin and then I applied 3 layers of fiberglass matting:









While waiting for the fiberglass to cure, I went to admire my SR components:



*drool*


I waited until the next morning. I took the mold off the a-pillars and cut them to my desired size. As you can tell from the pictures, I used a lot of resin.







Then I mixed body filler and fiberglass resin/hardener to apply over the now cured fiberglass







I did the same to both a-pillars:





While I was waiting for the mixture to dry, I started the speaker pods. I bought an extra pair of speaker grills for my Civic in case I ever wanted to go back to stock. I started by making sure they fit and cutting a small adapter for the drivers.









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Old 03-Nov-2008, 09:29 AM
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Next, I began gluing the adapter to the speaker grill which I cut out to fit the drivers. I had to test the location of the speakers in different places until I found the right position. After I found the right position, I used tape and glue to hold it in place. Then I used some small wooden supports and glued everything to place.









Then I used a stretchy cloth to cover the speaker pods. I didn't cover the middle since I was going to be cutting it out anyways (for the driver):







Next, I applied the resin/hardener mix to the cloth. I applied 2 or 3 layers and waited for it to harden:







While it was drying I moved back to the a-pillars and essentially did the same thing for the tweeters. It took some playing around and a lot of tape for me to find what I thought was the most ideal place for the tweeter. After I found that location, I used plastic can lids for tweeter mounts:









Once I finalized the location of the tweeter, I glued the plastic lids to the a-pillars:







Next, I used the same cloth to cover the pods:









Now it was time to apply the hardener/resin mix just like I did for the speaker pods:







As you can tell from the pictures, I didn't stretch the material enough, so it began sagging a little when I applied the resin. I waited for it to dry and then I used bodyfiller to even everything down (as you can tell I used too much hardener):




After I sanded it, it became a little more even:

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Old 03-Nov-2008, 09:29 AM
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Now both the speaker pods and a-pillars are at the same step of the process


It was now time to apply a coat of bodyfiller and resin/hardener for both the speaker pods and tweeter mounts. You might have also noticed that I cut the a-pillars a little shorter:











When that cured, I put sealant around the inside of the speaker pods to make them as airtight as possible:







Now the fun part! ... sanding. This probably took the longest. I began by using a dremel to cut/sand the ends of the speaker pods so they fit in the stock location. Then I began with 40 grit sand paper and sanded everything down to 600 grit. I applied some filler as needed and kept sanding.



















After all the sanding was done, I started applying multiple coasts of scratch filler and primer. I applied thin coats but put many layers until it was very smooth:







It was now Saturday night. I went out, but as soon as I returned, (it was about 1AM) I started applying coats of paint.







The next morning, I applied a few more layers of paint and 2 thin coats of clear coat (after the paint dried):



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Old 03-Nov-2008, 09:30 AM
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As soon as it dries, its time install everything! I started by taking out my momo components, door panels, and coaxial speakers:











I used two plastic cottage cheese bins to make a small enclosure for the drivers in the door. I only put a little bit of dynamat around them and put some polyfill in there. As soon as I get some more, I will do the entire doors:











Now it was the moment of truth! ... fitting the speaker pods and drivers! You can clearly see the size of the driver enclosure in the first picture, I also added some additional polyfill:





It fits!







I did the same to both doors and then I moved on to the tweeters. Since I didn't finish the tweeter pods properly, I will have to do that some other time (probably when I re-do my trunk). I'm thinking of covering it with suede or leather.



Perfect fit!






I fit the other side as well, and put the door panels, stock kick panels and everything back. As much as I liked my Q-logic kicks, its nice having a little more leg room and my dead pedal back

As you can probably tell, I didn't do such a great job with the speaker pods and tweeter mounts/a-pillars... But given the fact that its my first time, I'm still pretty pleased with the outcome.


Before:





Finished product!




The four channel amp in the middle is powering the front components:




Old momo's taking a rest before I give them to my brother:





Okay, now my opinion on the SR components, In case you can't tell, I have the SR6500's. I was so excited to turn on my stereo and listen to these babies... I kid you not, my heart was beating so fast and I just kept praying that I didn't mess anything up. I've had these components since around October and I've only installed them now, so needless to say I was very happy, and some might even say emotional at the same time

As soon as I started listening to some music, I was sooo amazed... especially by the tweeters. These tweeter are unbelievable. I honestly couldn't believe it. I don't know if it was more because of the tweeters or their new location, but they sounded amazing. They were very detailed, smooth and crisp unlike the momo tweeters which I found to be just a tad bit too bright. A lot of my favorite songs are by Metallica and I just couldn't stop listening. I must have sat there for at least 30 min on my driveway just listening to music. The drivers - even though they aren't broken in - sound very smooth as well. They blend in very nicely with my SR subs and the have a decent amount of punch too them. I expect it to be a little better once they are fully broken in, but I'm pleased with the way they perform now. At first, I didn't really know what to expect, but man, Polk really pulled through on this one. I love my old momo's a lot but these are just in a completely different class. I especially love love love this tweeter soooooo much.

Anyways, enough rambling from me for now. This is a long enough post as it is. I hope you guys enjoyed it and find it a little useful... pardon me once again for the sub-par craftsmanship. Feel free to ask me any questions!
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Old 03-Nov-2008, 09:30 AM
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Since my finishing looked like crap, I re-finished the speaker pods with black leather on Thursday. Hopefully I'll do the same to the a-pillars soon. The black suede I found I didn't like so I got some tan instead... I thought it would have matched better with my interior, but it didn't so I ended up using the black leather. I think it looks much better than before now (if I may say so myself). If anyone has any fiberglass/painting experience, please give me some tips on how to imporove. I want to do similar work in the future.








Oh, and if anyone's got any opinions on how to improve my painting, please please let me know, as I'm going to have to do it in the future when I fit the alpine w-505 into my dash.

Thanks in advance!

vid:
http://www.youtube.com/watch?v=OztYvOPa7QM
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Old 03-Nov-2008, 10:02 AM
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great job, although i do not like the speakers in the door panels. they are sticking out bit too much imo. but overall good job.
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Old 03-Nov-2008, 10:26 AM
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pretty good, but I would kick the speakers in everytime I got out of the car, lol
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Old 03-Nov-2008, 11:09 AM
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why is it you wanted the tweeters so far away from the mid and so high on the dash??
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Old 08-Nov-2008, 01:06 AM
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Originally Posted by trunk_munkey View Post
why is it you wanted the tweeters so far away from the mid and so high on the dash??
tweeters are supposed to be at about ear level...
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Old 08-Nov-2008, 04:11 AM
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I had my old tweeters in the kick panels and I found that it kind of dragged down the sound stage. I know I did a pretty bad job with the tweeter pods, but I'll be redoing it again sometime.
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Old 06-Feb-2009, 10:41 PM
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Nice work.. I wanna do something similiar to this, but much nice in my 1990 civic.



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Old 23-Feb-2009, 05:51 PM
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Thumbs up Nice

Yeah i did the same thing in my civic... well the a-pillar tweeters. Sand it down so the edges are level and wrap them in suede... i did my headliner in black suede, as well as all my pillars and door inserts. Now im trying to find acura el leathers and itll be like a little bentley lol. But nice going!!!
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Old 24-Feb-2009, 02:13 PM
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Originally Posted by Robb View Post
Nice work.. I wanna do something similiar to this, but much nice in my 1990 civic.



Yeah those look a bit tacky, they would have been much better if they were vinyl'd to match and and had grilles as well. I had davis from selective sound do a set of door pods in matching blue vinyl on my 90' sedan and they looked and sounded great!

Last edited by thrill_house; 24-Feb-2009 at 02:20 PM.
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Old 24-Feb-2009, 07:43 PM
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Originally Posted by spyda5588 View Post
tweeters are supposed to be at about ear level...
Since when??? the human ear really isn't designed to tell vertical position all that well. The mid and tweeter (unless you use some type of digital processing) should be as close together as possible. Also you put the speakers lower to get equal path lengths to your head.

Anyway..... great job on the pods. maybe do a skim coat on the tweeter pod to pillar. this will make the transition from one to the other smooth. Painting those surfaces takes some time and practice. Time when you first try doing them. With practice as I'm sure you already learned a ton, will give you the foresight to lay out differently to save time. oh one last thing, high build primer!!!

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Old 08-Mar-2009, 10:18 PM
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Good job on doing it, but that does not look good were they are. they stick out way to much.
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Old 07-Jun-2009, 12:54 AM
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As you may or may not remember from last summer, I attempted to fabricate my own tweeter pods and they came out terrible!

So here I am going for round two... here are a few pics... I've only been working on one side in case I learn something new along the way... any feedback? I didn't notice this until I looked at the pics, but it seems my sanding isn't very even.

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this is the paint i'm using:

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I also found the material I'm gonna use. Its like a cross between vinyl and leather.

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a few more pics:

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Old 07-Jun-2009, 08:55 AM
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Looks good. I would wrap the whole A-Pillar, I think it would look much better.
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Old 07-Jun-2009, 09:31 AM
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Thats a good idea. I'll do that if they dont turn out how I want them to. I appreciate the tip.
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Old 07-Jun-2009, 09:43 AM
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Yeah, it will look like it's all one piece. Then when ppl ask where you bought them from, you can tell them they are pure custom.
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Old 07-Jun-2009, 12:30 PM
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After I covered them they looked ok. not great, but i was pleased with them.

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Then after I installed them I got some air bubbles. Must have not used enough adhesive. I'll be taking them off sometime during the week to fix it.

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