Mini MINI Mini!

Introduction - explaining what I want to use for the new ICE Install.
Part 1 - Custom MDF Rings to Support the speakers.
Part 2 - The Fibreglass.
Part 3 - Redoing the Fibreglass
Part 4 - I Love Lycra

Well, much has not really changed since the last part, almost three weeks ago. So, why the title? Well, let me explain. In part four I had covered the front speaker pods in lycra and then resin. After that I used the same basic fibreglassing technique (detailed in part 3) to cover the outsides of the pods. There was one difference. Rather than use the scissors to cut up the CSM I ripped it. This gives better bonding between pieces when applying the resin and allows the CSM to wrap around the awkward shape easier. A few quick pictures to show my process:

The pod, wrapped in dry Chopped Strand Mat which had been ripped rather than cut with scissors. This was then carefully laid out on the bench and each piece was stippled into place with resin.
 
 
 
 
This image (right) shows the pod, covered in resined CSM and left to dry. I used the same stippling process as with every other step. 
 
 
 
 

I then tidied the dry fibreglass with a Dremel type rotary tool and removed the lycra from the speaker hole. This was where I realised that I didn’t actually like the pod. The pod was looking far too chunky, much more than I think would look good in the car. The next problem is point out by the arrow. How the hell would I get a covering (vinyl or carpet) to sit on that and look good? Simple answer? I can’t. So. These pods are now sat on the shelf. 
 

Enter attempt number two:

A simple circle of 12mm MDF as the backing, the same style front baffles, carefully guestimated angle and offcuts used with hot glue to hold the lot together. I love hot glue! 
 
 
 
 

Covered in Lycra. Rather than use the hot glue to hold the lycra in place this time I have been able to use staples on the MDF mount. This has meant that I could fiddle with the lycra more, pulling it tighter here, letting it off a bit there and generally making it much neater. I know I still have a few pits where the lycra has stretched between the rings but I am much happier about putting FG filler over this to skim it rather than bulk the application I would have had to do on the old ones.

And finally (almost) for this part, the new pods covered in polyester resin and hanging up to dry. Almost? Well, there’s no more I can do to the pods until the resin is dry. I have in the meantime been able to get my Elemental Designs subwoofers mounted:

Looks crap right now yes? Of course it does. I have screwed the subs into the board and thrown it in the car. Yes, it will look much better when it’s finished. I have done this to be able to test them to find out the capabilities. They are running on a Vibe Blackbox 2 amp without and boxes behind them. They are quiet.

Video of them in (quiet) action:

They sound ok but for a few things:

1. They will absolutely need boxed. I just need to figure out the space under the rear seat.
2. They will need (ideally) about twice the power I am giving them.
3. I would like to scope the outputs to eliminate any clipping on the signal from the amp.

Does anyone have an Oscilliscope I can borrow?

Oh, a quick shout to all the fab SQ guys, bass heads and fabricators at Talk Audio. I have so much in the last fortnight that my brain is swimming with information. Before you go and look and get scared about posting (like I did), although you see lots of talk about £500 speakers, £1,000 amps and talk of 150 decibels, these people are quite happy chatting and advising even about the cheapest of budget installs, like mine! Thanks guys!