AudioGal, I'm looking to do something similar with door pods. It's been looking to me like I'll need to simply cut the bottom portion of the door cards off to attach the boxes, but you appear to have successfully cut a hole in the cards to accommodate the boxes. Would you happen to have any additional photos of how you did this? Does the box attach to the door, then the card simply fits over it? Your work looks excellent, much better than I anticipate mine ending up if I lop off the bottom. Without knowing what audio qualities that each of your solutions yielded, I loved the extreme, pushing-the-limits insanity of your previous setup, although I think I'd personally rather live with your newer, stealthier, more compact config.
Thanks for continuing to update us on your vehicle, it's one of my favorite builds.
Why thank you hella356 😊 and ya push the limits and try stuff out and live on the skinny branches , that is where the fun is anyhow!!
Ya i needed to fit the bigger magnet so the extreme enclosure had to go, that being said, the current enclosure performs very very well , and integrates with the dash speakers extremely well.
Based on my door design i decided to try and do an insert style. It was tricky and took a lot of fiddling and i went slow to ensure a tight fit. I think i have pictures earlier in the thread so have a look but the general idea is this and it is all about creating indexing points to index the door to the door panel and the enclosure. With the indexing the enclosure and door panel all have the exact same refence points.
I used two door panel attachment holes and one of the original speaker mounting holes as my index points.
I then created a flat template that would be the shape i wanted and as large as i needed. this took a lot of fiddly measurements but well worth it. the template was made out of 1/4 particle board or something like that. the template had mounting tabs at the three locations on it that where the exact same tabs i was going to use on the enclosure.
this template was used to dimension the enclosure by flush trimming the door mounting plate of the enclosure to the template. that became the shape that would poke through the door panel.
Since the door panel shared 2 of the three mounting (index points) as the door and the enclosure i could lay the same template panel on the back side of the door panel using the index points with dowels inserted. laying the template on the back side of the door skin i created a outline (using marker) of the template . I then nervously cut out the line on the inside ( margin of error) and i had the basic hole.
The basic enclosure outside dimension (back and walls) was built and using the indexing tabs laid it on the back if the door panel and finished the second roughed in cutout for the actual enclosure on the door panel. Sine the index holes where also the door card (panel mounting holes ) there was minimal opportunity for movement or misalignment. I did this for each side of the front doors.
Then I mounted to the door using 1/4 machine bolt nutserts . I them went through the process of putting the door panel on and finish out the final cut to allow for covering materials and trim pieces.
I took a lot of measurements, did more test fitting than i could count and all that type of stuff. For a raw amateur I am really happy wit how they turned out. The performance is excellent and the rattles from the door are minimal and easily handled with standard deadening and closed cell foam , etc..
Hopefully that makes some sense, if not ask away and i will do a better job of explaining