Zv4 18 in a 2004 Pontiac Vibe (Full Build)

[Julian 641]

Honestly 12 gauge is probably way over kill, 14 or 16 gauge would probably be best. You're gonna have one hell of a time routing it through the door. Lol

[Corey Wagner 7]

Nah, door panels are already off.  I deadedned them and I see where I am gonna run it all.  The big change today is that I decided to fiberglass the doors and put both component sets in the front stage.  This is going to take me a bit because of two reasons. 1) I live in an apartment so I am doing all of the fabrication on my balcony or in the parking lot.  2) I have never done door panels before, just watched youtube videos and read about it on forums.  I am pretty handy so I am sure I can figure it out.  

[jcarter1885 995]

Today is the day for progress.  Door panels are off, deadener is being applied.  I am starting to wonder if I bought the wrong amp though...  Everyone that posts a video has a 3500 amp on their sub; I just wonder if my BC2000D is going to be enough.  

 

Dont worry about what everyone else is doing, just make sure you build an efficient enclosure and your good to go. I wouldnt put 3500 watts on a sub for daily but to each its own.

[Corey Wagner 7]

I am making speaker rings right now.  So many cuts.  Wish I had a plunge router and jasper. 

[Corey Wagner 7]

This is my garage where I work on everything...

 

 

 

 

Let's see what we are working with.

 

 

 

 

What is that?  Do you see what I see?

 

RIVOTS!!!  Oh well, break out the drill!

 

 

 

 

 

Scond Verse, same as the first!

 

 

 

Now this is my workshop.

 

 

 

Just check out that view!

 

[Corey Wagner 7]

Here is where I tried a few different ideas trying to get the best end result.

 

 

 

Not bad, but something is missing...

 

 

 

 

Yup, you guesed it.  I forgot to make the step down rings so it sits flush to the door.  Back to the cutting again.

 

 

Losing daylight, time to move inside.

 

After I came inside I started to mock up how I wanted the speakers to sit.  The one thing I want to do is incorporate the grills from JBL.  I think they look amazing.  The problem is, they won't work with the rings that I cut last, so I ended up using the first set I made without the flush mounts.  Like I said, this is a learning experience for me.  

 

 

This is how they sit right now, I am just adding the rest of the braces to finalize the set up.  More pics to come.

[Corey Wagner 7]

After messing around last night for a bit, I decided to not use the speaker grills (even though I like them) and use the flush mount rings I made.  I was looking at pictures on a google image search and it just looks a lot better to me when they aren't surface mounted.

Edited May 11, 2014 by Corey0927

[Sencheezy 689]

Nice progress so far sir!!

[Corey Wagner 7]

Thank you.  I now have everything I need to finish the install.  I just need time.

[Corey Wagner 7]

This is how it sits currently.  Just trying to decide on where to mount the crossovers.  If I want to keep them on the door, or next to the amp.  I am thinking for the sake of running all of those wires, putting them on the door will be easier in the long run.

 

Edited May 11, 2014 by Corey0927

[emh9009 199]

Build looks good! If something doesn't work adapt and figure out how to make it work. I had those components a couple years ago, sold them to a friend and he is still using them today. Went through a couple pairs of tweeters though haha

[Corey Wagner 7]

It has been raining here for 5 days.  Today was the first day I was able to do any sort of work on it.  When I was mocking up the speaker rings, I didn't like the setup.  The rings were cut with a jigsaw and are not perfect.  I am worried that this will show when I glass over them.  I ordered a Jasper Jig today and went out and bought a plunge router.  This should make me happy once they are perfectly round. 

[Shogen 325]

looking real nice!!!

[///M5 2,833]

You are attaching those rings to the door and not the door card right?

[Corey Wagner 7]

You are attaching those rings to the door and not the door card right?

Explain what you mean.  

[jcarter1885 995]

Door panel equals door card and actual door, means the metal skeleton behind the door card (Usually the factory mounting location).

[Corey Wagner 7]

I drilled holes in the door panel.  After that, I glued fiberglass mat to the back of it.  Then I glassed the front with enough resin to fill the holes and soak through to the back mat.  

 

Front:

 

Back:

 

After this sets up, I am going to add another layer or two of mat and then the rings will be put in place.  I plan on stapling the fleece around where the green tape is and use bondo to make the transition smooth.  

 

I am pretty confident that this will work, but if it doesn't I can always just start over. It is a learning experience for me. 

[Corey Wagner 7]

Front:

 

Back before I applied any resin to it:

[Corey Wagner 7]

This has been a long few weeks.  My father just finished his 6 weeks of radiation treatments and we are just waiting for his follow up MRI to find out if it worked or not.  As far as the car is concerned, I have hit my second wind now that I know he is done with his stuff.  I started working on the doors again yesterday.  Here is what I have so far...

 

Rings glued down, waiting for fleece.

 

 

Fleece on

 

After mat applied.  (Yes I know there are bubbles.  This was my first time doing this and I have learned a lot so far)

 

I trimmed the edges away and did several test fits in the car and everything looks good for clearance.  I am going to start the bondo work right now and hopefully finish them up this weekend.  As for the crossovers, I decided to mount them to the back side of the door panel so they are tucked out of the way.  

[Corey Wagner 7]

Passenger door bondo done.

 

[Corey Wagner 7]

As I am looking at these I am am thinking that my original idea of wrapping them in vinyl is going to be a bitch with the curves.  I am now thinking I will plasti-dip them with matte black.  It will be a lot easier and will still look good.

[Corey Wagner 7]

Update: 6/28/14

 

My dad just finished 6 weeks of radiation treatments and IT WORKED!  The tumor is disintegrating and he is probably going to make a full recovery.  I wasn't able to do much work with the hectic schedule of driving him to his treatment every day for 6 weeks.  Now that things are settling down a little, I was able to work on the doors for a couple of hours today.  

 

It is definitely a learning experience for me.  Overall I am happy with how it is going.  If I was going to do it over again, I know what I would do differently.  Anyway, on with the pictures...

 

 

Test fit to make sure everything still shuts properly.

 

Beautiful!

 

I am going to be working on these tomorrow for about 8 hours, so I should be sanded down and ready to paint by tomorrow night.  Thank you for everyone who has tuned in for this build and a special thanks for those who have said kind things about my dad.  This build should start moving along nicely now that I have time.

 

Corey

[jcarter1885 995]

Glad to hear about your father man, hope all turns out well.

[emh9009 199]

Congrats to your Dad and family! Your door pods are coming along very nice!

 

Side note: don't use black text, as it's harder to read on dark background.

[Corey Wagner 7]

On my screen it shows as black text with a white background.