Chevy Cavalier, Kerfed Port Build, 12" BTL

[antonmiller 8]

Hi All,

A while back I had come up 2 designs to build for my 12" BTL. Click Here for Topic on Box Designs

This next thing is quoted from the topic on the box designing.

ok so i think im just going to build box boxes and see which one perfroms better and then report back here when the results are done. so ive design up 2 boxes both tune to 34 hz with about the same port area. and they box have almost the same interior volum they are off by about .06 cu ft (like nothing).

so first here is the top gap box that i design its port is 11.25 high x 3.75 wide x 32" long and the interior volume is 2.4 cu ft. it will leave a gap of about 3.5" by around 20-23 inches long on the top. it also features a 2x4" on the back of the box for support as i couldnt get a support inside the box...

next is the side gap box. its port is 14.5 high x 2.875 wide x 32" long. it has 2.46 cu ft internally and will leave about a 8-9"" gap by 10-15 inches tall (angled sides) on the driver side. it also has a nicley rounded edge for that side of the box, i would assume it would help with flow.

please all comments and concerns welcome i just want to do it right.

so this past week we started the build. pics below.

so we started by trial and error on the kerfing. failures are below.

then we finally got it right. we did .25" spacing for 4 inches, it should be a total of 17 cuts. and we also left about 1/32" of wood left. very thin.

so after we got that right we finally started cutting the kerf for the other boards.

we then ran into a snag with the paint can. when we opened it up it was broken. so since its easier to paint the pieces when they are not assembled on the box. we had to make do.

here are some quick mock ups of what it will look like.

now some assembly shots.

more to come. this is as far as we got. next week end like not this up coming, but the one after they should be done.

[thebiggmann12 14]

looks awesome.

[masterofallbass 0]

nice bud, very nice

[DD9915D!!! 5]

HELL of a box!

[antonmiller 8]

forgot a couple pics. just found them. mainly assembly shots. i will be cleaning up the edges of the box. dont worry about that. lol

[TheSundownFire 0]

Hello friend.

Im watching this.

Ever thought about flaring the top too kinda like ***** *****'s "Squaro" port in his Honda?

[antonmiller 8]

Hello friend.

Im watching this.

Ever thought about flaring the top too kinda like ***** *****'s "Squaro" port in his Honda?

flaring the top would get too tall. i will be rounding the top and bottom with a router though. you know with the j's there isnt much room in the trunk for doing much. and one box is maxed out to just fit through the back seat hole and get in the trunk. and the other i wanted as short as i could get it to test my theory's.

[todd.brust 29]

Holy good God! That looks great and that's a huge understatement. It makes me feel bad about myself, because i have the resources to make stuff like this and never take advantage!!! Nice build thought. Looking forward to seeing the completed enclosure.

[AccordSiR87 2]

Awesome designs and nice work so far.

mmm. wish i had the tools to do some wicked woodwork.

[Mac N Cheese 90]

Ready to see it finished

[antonmiller 8]

Awesome designs and nice work so far.

mmm. wish i had the tools to do some wicked woodwork.

yea me too!!! lol that is my friends grandpa's table saw. very nice piece of equiptment!

Ready to see it finished

you and me both!!

Holy good God! That looks great and that's a huge understatement. It makes me feel bad about myself, because i have the resources to make stuff like this and never take advantage!!! Nice build thought. Looking forward to seeing the completed enclosure.

if you guys down there in winona have another comp this summer you can see it in person

[tehbert0 0]

did you glass the kerf or anything?

ive never done one so i dont know how strong they are

[antonmiller 8]

did you glass the kerf or anything?

ive never done one so i dont know how strong they are

yea we poured resin down the slits of the kerf. after it dried we tried to push on it and see if we could move it. and it didnt budge. its not like it needs to be strong or anything. there is a corner piece that protects it from all the pressure anyways.

[mccleery3 166]

Nice looking enclosure bro! I'll be waiting to see the finished result on this one

[1200 bandit 2]

Nice work looks super keep the pictures coming.

[TheSundownFire 0]

I approve. Continue.

[Julian 641]

great job

Edited November 30, 2009 by Julian

[antonmiller 8]

the build will continue this friday or saturday. and be finished by sunday (hopefully) and i should have videos up then. but for now i have a week of working and then the weekend is dedicated to this project.

thanks for all the comments!

[porkchop 304]

lets see the finished product bro!

so far it looks dam nice.

chop

[masterofallbass 0]

i want more pics... NOW!

[mccleery3 166]

MORE!....get to it man

[Kanaworm$ 292]

Nice job on the box! .... But we need more pics!

[mbarber25 29]

that box looks nasty

nice work

[antonmiller 8]

yea we didnt get much done this weekend due to temperature conditions and power outages. but i do have some progress. i will post pics when i get home after work tonight. basically all we did was get one box all the interior boards in and fiberglass it again. but due to lack of hardener and poor temperature conditions in the room it didnt harden up fast enough to be able to get good progress on it. it was like under 50 degrees in the room. i know horrible.

[masterofallbass 0]

yea we didnt get much done this weekend due to temperature conditions and power outages. but i do have some progress. i will post pics when i get home after work tonight. basically all we did was get one box all the interior boards in and fiberglass it again. but due to lack of hardener and poor temperature conditions in the room it didnt harden up fast enough to be able to get good progress on it. it was like under 50 degrees in the room. i know horrible.

FAIL! Jk bud. I just want more picz