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Old 10th May 2009, 17:28   #1
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Default My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen

Well folks, the story goes like this...

Sold the Saaki (Esteem) and then came in the White Horse (Zen). I transfered all the ICE from Saaki to the new car. One new thing that I added was the Polk momo 5.25" components. As per the installer, this size was the max that could go in without mods. All well, till 1.5 months after which the door pads jarring started even with damping already done.

Okay, before we proceed further, I want to make a point that I dont run any high end ICE. This is what I have.
  • HU: Pioneer DEH-5090UB
  • Rear fills: JBL GTO 937 Special edition
  • Front: Polk Momo MMC5250 5.25" components
  • Sub: Pioneer 800 watt single coil
  • Amp: Pioneer 300 watts
  • Pioneer Steering remote
  • Wiring: hitrous and efx
I am totally happy with the way it sounds. But I wanted some bling to the install and this is what we did during the install.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0039.jpg

However, a week ago the left door pad was vibrating quite a lot at high volumes. I removed the door pad to find out that it wasnt the doorpad. It was the MDF spacer that was loose and dancing with the compos on. I had to remove the compos to tighten the spacer. I was shocked at what I saw.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0053.jpg

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-p100509_16.23.jpg

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-p100509_16.24.jpg

The compos were fitted in such a way that the door pads doesnt lock properly allowing the water to enter and the spacer was all wet with it(It can never dry as I wash the car everyday). Not just this the stock grill was pressing the woofer itself (Notice the marks in last 2 pics). This was the same case with both the doors.

This was enough to spoil my weekend. I was upset with the installer. I really didnt pay attention during the install as I had a lot of confidence.

Now, with all this I had to remove the compos immediately to avoid any further damage. I sat for a week and thought that I need something that satisfies me with the sound, No door pad jarring, no water issues, no space issues with compos in the stock location and I need a Bling.

I thought harder on what i need, the materials required, the cost etc etc.

Here is what I bought and then began the project.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-p100509_11.44.jpg

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-p100509_11.39.jpg

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-p100509_11.40.jpg

Breakup of the cost:

Fibreglass Mat: Rs 245 (2.5 kgs)
Fibreglass Resin: Rs 500 (5 kgs)
Accelerator: Rs 52 (1/4 Kg)
Hardener: Rs 42 (1/4 Kg)
Sand paper 2xP80 & 2xP220: Rs 50
1 inch Masking tape: Rs 30
Body filler and hardener: Rs 223 (1 Kg)

Total: Rs 1142/-

Stay tuned.....

Last edited by shreyasma : 10th May 2009 at 17:29.
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Old 10th May 2009, 17:47   #2
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But why have you bought yourself a crotch guard? Too much watching IPL eh?
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Old 10th May 2009, 17:50   #3
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This one is going to be very interesting.

What is it that you are going to do???

Tuned....
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Old 10th May 2009, 17:59   #4
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Looks interesting! Speaker pods?
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Old 10th May 2009, 21:22   #5
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looks quite good to me, when will we see the final outcome.
waiting eagerly for the same.
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Old 10th May 2009, 21:58   #6
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@ shreyasma, where did you pick the fiber glass stuff from in banglore?
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Old 10th May 2009, 22:16   #7
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Aah.. something that I could take some inspiration from !
We are waiting - Tuned & Subscribed for.

@sam - you and your jokes.
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Old 11th May 2009, 00:06   #8
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The fibre glass stuff was picked up in VV puram near sajjan rao circle. I will PM the address if needed.

I am into making speaker pods as you all might have guessed. Work began this afternoon.

I will not be using wood in the pods except the mounting rings.
What you see below is the base for the pod that will be fitted to the door pads.

Here are few pics...

I took the shape on a old news paper and reversed it for the other door
My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0054.jpg
As I needed a plain surface to begin, I spread the newspaper on the floor. I have also spread some plastic sheet over the news paper so that the resin can come off easily after drying.
My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0055.jpg
This is after the 4th layer. I couldnt take pic in between as I had the gloves on and had the resin on it.
My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0056.jpg

Tomorrow, the base will be ready and the pod further takes shape. Will post pics tomorrow at the end of the day.

Well, I need the help from you guys to source the carbon fibre replica vinyl. It looks exactly the same but its just a print on the vinyl. Its easy to stick and heat for a wrinkle free application.

Thats it for today...
See you tomorrow. Same time, same place
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Old 11th May 2009, 00:26   #9
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great great job. am a fan shreyas!!

CARBON FIBER 2 II Vinyl Roll Adhesive Film 25" X 8FT:eBay Motors (item 180290216150 end time May-14-09 19:20:43 PDT)

here, this should sort you out. will cost you about 2.5k and you can spend about 5-600 more for one week shipping!
cheers!
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Old 11th May 2009, 00:50   #10
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sam you never run out of humor do you? another classic one!
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Old 11th May 2009, 08:35   #11
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Thanks for the info, you using bi-directional mat or uni directional? they have different properties.
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Old 11th May 2009, 09:07   #12
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ah! nice thread. Gonna keep a close eyes on this.





cheers
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Old 11th May 2009, 14:26   #13
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Quote:
Originally Posted by shreyasma View Post
The fibre glass stuff was picked up in VV puram near sajjan rao circle. I will PM the address if needed.
Yes sir, please PM the address to me too!
Quote:
Originally Posted by shreyasma View Post
... Well, I need the help from you guys to source the carbon fibre replica vinyl. ...
Try at Jansons on JC Road (in front of the Corporation multi-storeyed parking). If he doesn't have it, he will be able to source it for you or tell you who has it.
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Old 11th May 2009, 17:33   #14
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nice DIY going on.
i need to stick to this thread. all the best. and please make sure you dont make any mistakes as i will be highly inspired by you while working on fiberglass, hehe!
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Old 11th May 2009, 20:21   #15
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So after getting really dirty, here are the updates

Started to cut off the base as it was completely dry. Used the dremel tool

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0059.jpg

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0061.jpg


Then made marking for the clamps that will project the screws outside the base. This is useful for mounting the pod onto the doorpad.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0062.jpg

Clipped both the bases in reverse to get the holes exact. Also placed a cardboard in between. This cardboard helps for making the holes in the doorpad correctly.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0065.jpg

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0066.jpg

Holes done and screws mounted.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0067.jpg

Made the crossover housing in cardboard. I didnt want wood . Notice the gap at the base. We will not have a sealed enclosure if I dont fibreglass. I am looking at little perfection and quality in sound.

Also notice the m-seal on the screws. This is to lock the screw in place as after finishing, there will be restricted access to turn them. Also put few drops of super glue before m-seal.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0070.jpg

Had to stop clicking pictures as I didnt want a fibreglass camera .

Anyways, Pods done and kept for drying. 6 Layers went in. Here is how it looks.

My White Horse - Project BLING! BLING! BLING! - DIY ICE for Zen-image0071.jpg

I will try to give some updates during the week. Else, kindly wait till Saturday.
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