SLOW build on a 2001 GMC Jimmy

[altoncustomtech 773]

dude thats awesome! 

Thanks! It's coming along a bit at a time.

[altoncustomtech 773]

Another small update.  Got started cutting the holes out for the plexi windows.  Just as I had planned (and really hoped) for they line up perfectly from the double baffle layer to the enclosure layer which really takes a lot off my worries about the enclosure turning out right.  So far so good!  Onto a few pics.

 

 

 

Got the holes cut out.  I hate using a jigsaw for anything, but I couldn't figure out a good way to do it with a router or anything else that would make a better cut.

 

 

 

 

 

 

 

I doubt you can see a difference in the pictures but this is the holes in the panels after sanding them smooth.  Whether it can be seen or not it has them nice and smooth and ready for the round over bit.

 

 

 

 

 

 

 

Here's the first hole cut out of the enclosure for the plexi.  Still need to cut the other two and sand them smooth.  

 

 

 

 

 

 

 

 

 

 

 

Alright, that's all I have for today.

[altoncustomtech 773]

Another little update.  Got all the holes for the plexi windows cut out.  Everything has turned out well so far on these.  I also got the edges of the plexi windows rabbeted today as well.  The table router I bought used from a friend really makes doing that sort of stuff NICE.  I used some practice pieces of wood to get the depth just right then just went to town.  I had all three pieces rabbeted in about ten minutes.  Tomorrow I'm going to rabbet the holes in the enclosure the same (3/8") depth after sanding the openings and then it will be ready to seal them with silicone, glue the double baffles on, and get the holes cut out for the sub and PR's!!

 

 

 

Hole number two cut out.

 

 

 

 

 

 

All three cut out.

 

 

 

 

 

 

Here's a shot with the first one rabbeted and the second one getting ready to be done.

 

 

 

 

 

 

Here they are resting in their perspective locations.

 

 

 

 

 

 

The last two pictures here show where just a little tiny bit of sanding will be all they need to slip right into place.  Once they fit down in there correctly I can rabbet the enclosure to match and when thats all done the plexi windows will sit perfectly flush (ideally just a few thousandths of an inch above flush) with the rest of the enclosure when dropped into place.

 

 

 

 

 

 

 

 

 

 

 

 

Well, that's all for today.  If I can get through the aforementioned steps tomorrow it's all downhill from there.  Sanding, rounding the edges of the enclosure, more sanding, body filler, more sanding, more body filler, more sanding, primer, more sanding, more primer, more sanding, painting the interior of the enclosure then applying the bed liner to the outside to finish it!

[altoncustomtech 773]

Another update.  It's really starting to come together now.  Instead of going through the spill I'm just going to post of the pics.

 

 

Got the holes sanded so the step in the plexi would fit.

 

 

 

 

 

 

Here the center hole on the front is rabbeted.

 

 

 

 

 

 

I used my hole cutting router with it's 1/4" upcut spiral bit to work the corners in and the plexi fits like a glove in it's hole.

 

 

 

 

 

 

All three holes rabbeted.

 

 

 

 

 

 

All three windows fitting in their respetive locations.

 

 

 

 

 

 

Putting in the silicone to seal the plexi up.

 

 

 

 

 

 

Had to work fast to get everything put together so no pics of the entire process, but here it is with the double baffles on and the plexi is now forever locked into place.

 

 

 

 

 

 

 

 

 

 

 

 

Tomorrow should end with the sub and PR cutouts made and the beginning of all the sanding to prepare for the body filler.

[MikeMartel 64]

Looking badass man.. Lovin it so far!

[porkchop 304]

Absolutely impressive beyond words as usual!

[altoncustomtech 773]

Looking badass man.. Lovin it so far!

 

Thanks dude!

 

 

Absolutely impressive beyond words as usual!

 

Thank you bro!

 

 

 

It's not as perfect as I had hoped it would turn out.  The corners of the windows in the double baffles didn't come out as close to perfectly rounded as I had hoped.  I worked hard trying to sand them and get them perfectly round but to no avail when I rounded the edges with the router it made them stick out like sore thumbs.  Then I put just a little too much silicone in the first hole, which with it's glove like fit caused to to hydro lock into place 1/8" or so above the surface of the enclosure.  Even after pulling it out and wiping off as much of the silicone as I could it was still having that issue a little bit.  I got it down in there VERY close to where it was supposed to be (less than 1/32" above the surface of the enclosure) but it still bugs me.  Hopefully these problems won't lead to any issues with the enclosure at a later date but only time will tell.  Like I said, it's not going quite as perfectly as I had hoped and planned, but it's not gone too horrible either.

 

I'm really just glad to finally have good, measurable progress!!

[EPerez 236]

OMG!!! It's almost done and looks amazing!!!! It looks perfect Alton great job. You definitely have skills!

[altoncustomtech 773]

OMG!!! It's almost done and looks amazing!!!! It looks perfect Alton great job. You definitely have skills!

 

Thanks!  Though I would chock it up to what little experience I've had in the past and the patience I've gained for doing this over the years.  Skills are attained through years of knowledge, practice and an aptitude for doing them.  What I have is a basic understanding of the way it should be done and enough knowledge, practice and aptitude to have it work out for me on some occasions.  lol

[altoncustomtech 773]

Another good update!!!!

 

Got to cutting the sub/PR cutouts today!  Only got one done, but it's well on it's way!!  Hopefully I can talk to 'ole lady into letting me spend time away from her and the kids this weekend and finish the other two cutouts.  Onto the pictures.

 

 

 

A little practice to verify the hole sizes.  Good thing I did that too, found I needed to make the OD cutout 11 1/16" to clear the gasket good and that the cutout for the frame to fit in had to be 9 3/8" and that's a super good snug fit too.

 

 

 

 

 

 

Spent time this morning sanding the hell out of all the sides to get it perfectly smooth, very little repair work should need done with the body filler.  Otherwise this is the pin for the jig in place.

 

 

 

 

 

 

Working on all the cuts to get the flush done.

 

 

 

 

 

 

Flushing is all done, time for the cutout.

 

 

 

 

 

 

Halfway through an inch and a half of wood.  Damn.

 

 

 

 

 

 

All done.  Left it paper thin so the cutout wouldn't drop, unfortunately I discovered the hard way that's not a good idea with plywood.  

 

 

 

 

 

 

Cutout is all done.  Had to sand down and clean up where the last little bit of the layer splintered from the knife.  I'll be spreading a good deal of glue on the inside around the hole to help with any integrity issues, I hope.

 

 

 

 

 

 

Finished sanding the mounting surface so it's all nice and smooth for a great seal.

 

 

 

 

 

 

Test fitting the PR in place to ensure everything was good, and it was perfect.  Fits like a nice tight glove.

 

 

 

 

 

 

 

 

 

 

 

There it is.  I love getting something done on this!!!

[Quentin Jarrell 671]

I hope you compensated for bed liner thickness.

[altoncustomtech 773]

No need. The bed liner will not be in the holes at all, only paint. The holes will be taped off and I'll be applying the bed liner with a brush and roller like I did the amp rack.

[mccleery3 166]

Nice! They sit soooo nice!

[altoncustomtech 773]

Nice! They sit soooo nice!

Thank you brother!

[mccleery3 166]

I really hope you are able to make it to Slam bro! I want to see this in person & need a demo

[altoncustomtech 773]

I really hope you are able to make it to Slam bro! I want to see this in person & need a demo

I'm trying really hard to force the stars into alignment for it. There's still a lot that needs done with the enclosure to get it finished and work is always an issue but I really want to make it this year with the Jimmy done.

[altoncustomtech 773]

Another small update!  

 

Got the edges of the box rounded and the last two cutouts done.  It's time for the body filler and sanding, sanding, and more sanding!  Onto the pictures.

 

 

 

 

 

Here's a couple of shots with the edges rounded over.

 

 

 

 

 

 

 

Got the second PR hole cut.

 

 

 

 

 

 

Here's a few with all the cutouts done.

 

 

 

 

 

 

 

 

 

 

 

 

 

Well, that's a little done, though now it's down to the fine stuff.  Overall it's turned out well and very close to the design.  I can't wait to get the thing done and in so I can hear for myself what that XCON can do!

[pmureika 31]

[altoncustomtech 773]

 

 

  

[AXEHAMMER 16]

Damn fine work Alton!

[altoncustomtech 773]

Damn fine work Alton!

 

[mccleery3 166]

Awesome craftsmanship!

[nem 2,019]

That is going to be gorgeous!

[altoncustomtech 773]

Awesome craftsmanship!

 

Thanks brother!  I'm hoping the trend continues.

 

 

That is going to be gorgeous!

 

Thank you so much!  It's not going to be perfect but if it breaks even with gorgeous I'll be more than pleased.

[gprestonmoto 89]

Wow going to be rad.