10th May 2009, 17:28
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| BHPian  Join Date: Jan 2007 Location: Bang!
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| 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.
 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.    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.    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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10th May 2009, 17:47
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| Distinguished - BHPian   | |
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10th May 2009, 17:50
| #3 |
| Senior - BHPian Join Date: Dec 2007 Location: Bangalore
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10th May 2009, 17:59
| #4 |
| BHPian  Join Date: Aug 2007 Location: Mohali
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10th May 2009, 21:22
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| Senior - BHPian  Join Date: Apr 2008 Location: in the car!!!
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10th May 2009, 21:58
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| Senior - BHPian Join Date: Mar 2006 Location: goa
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10th May 2009, 22:16
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| BHPian  | Aah.. something that I could take some inspiration from ! We are waiting - Tuned & Subscribed for. @sam - you and your jokes.  |
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11th May 2009, 00:06
| #8 |
| BHPian Join Date: Jan 2007 Location: Bang!
Posts: 652
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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  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.  This is after the 4th layer. I couldnt take pic in between as I had the gloves on and had the resin on it.  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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11th May 2009, 00:26
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| Senior - BHPian  | |
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11th May 2009, 00:50
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11th May 2009, 08:35
| #11 |
| Senior - BHPian Join Date: Mar 2006 Location: goa
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11th May 2009, 09:07
| #12 |
| BANNED Join Date: Nov 2008 Location: panchkula
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11th May 2009, 14:26
| #13 | ||
| Senior - BHPian  Join Date: Mar 2007 Location: Bangalore
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11th May 2009, 17:33
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11th May 2009, 20:21
| #15 |
| BHPian Join Date: Jan 2007 Location: Bang!
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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   Then made marking for the clamps that will project the screws outside the base. This is useful for mounting the pod onto the doorpad.  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.   Holes done and screws mounted.  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.  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.  I will try to give some updates during the week. Else, kindly wait till Saturday.  |
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