when i moved out to california, it was a complete reversal, as i would say a good 85 percent of the cars we work on are 5 years or younger....kinda odd when i think about as california weather is certainly better for preserving older vehicles and burgh.
So it is actually delightful to work on an older vehicle once in a while...and this project, features a very cool ride indeed: an 1990 Porsche 964 Carrera 4.
Jesse and JOey teamed up on this project while i just did the final tuning...and what made it really cool in my opinion is that while the car is for sure older tech, the system we installed utilized some neat new technology, like the Mosconi AMAS BT streaming and a customer supplied Pono player by neil young.
First off, the goals:
1. to achieve a nice level of sound quality but still maintain the traditional interior appearance of the vehicle (no door pods, no dash pods etc)
2. delete rear seat but preserve a durable perch for the customer's best friend to sit on during rides as she LOVES taking trips in the 964!
3. integrate the Mosconi AMAS2 and Pono player into the mix as main signal sources.
Lets get started:
here are three pictures of the car itself, i have a soft spot for older porsches, as does JOey, so this was quite a treat to have in the shop, i have never really seen a 964 carrera 4 in person before...love the proportions!
First up are some pictures of the battery fusing termination upfront. Jesse fabricated a metal bracket, tapped to allow the stinger fuse block to bolt in, and then it self bolts into a rivetnut at the front of the car. the main power cable is then run into the interior and loomed and secured along the way.
After some discussions, it was decided that the Blaupunk Reno II radio would be kept in place, as really, any other unit that is available now would look a bit out of place. instead, we decided to utilize the mosconi AMAS module and a Pono player as the main signal sources. To make this work required two things, a Mosconi DSP controller upfront to provide master volume and other controls, and also a mini jack that is inputted into the DSP as that is the only output the Pono player has.
the hard part here is fabricating a DSP controller mount that looks like it belongs in the car, but still places the controller at the finger tips of the driver.
I think Joey came up with an awesome solution. it takes place of the original as tray and painted to match the rest of the interior. there is also a mini jack port on the passenger side of the housing to allow the Pono player to plug into. here it is:
here is the pono player plugged in:
and here is his iphone, which is the other main signal source that streams via the mosconi AMAS:
it should be noted that the Blaupunk headunit is still hooked into the system so the customer can use it to listen to radio from time to time if he needs it. With this setup, the customer also gained hands free bluetooth capability throughout the car via the AMAS' hands free mic setup.
lets take a look at some build pics of this mount. first, a mold was taken of the stock astray door. this provides a solid mounting base for the pod itself.
he then fabricated the main controller housing out of acrylic, and blended it in with the base portion:
so how this work is that the controller actually bolts to the base portion which is then bolted to the car, while the housing is a slip on cover that secures to the base. here you see that break down:
he then soldered a mini jack port and lead out RCA leads:
the base portion, after sanding, is then upholstered, and the controller mounted to it. you can see the mounting and interlocking system in these pictures:
here is the base bolted back into the car, with the DSP controller cable andt he rca cable for the mini jack port lead through:
and then dsp controller was wired up and bolted in place, after this, the mini jack was simply hooked to the rca cable, andt he outer housing slipped on and secured:
moving onto the front stage. as mentioned the idea was to have a nice level of sound quality but still maintain an oem appearance. So here is the finished product...from afar, it looks very stock:
but look closer and you will spot a Morel Titanium Elate 6.5" midbass on the bottom with a mesh grille that Morel sent us instead of the usual octopus grille that it comes with, and a Morel Supremo Piccolo tweeter in the oem tweeter housing:
similar view of the passenger side:
Jesse did the front stage work and while the end result looks very simple, it was actually quite a bit of work. first, new wires were run into the door and the door sound proofed with a combination of STP cld damper and Focal BAM. Since the oem door card literally sat right on the metal skin in most places, the normal layering process we do isnt feasible.
the outer door skin also got their share of blackhole tiles, and note the four rivet nuts installed into the metal around the speaker opening.
the same process on the passenger side:
now to properly locate the speaker...what needed to happen was that the door card opening was enlarged a little bit, the oem weather barrier cup was removed, and then a spacer baffle was needed in BETWEEN the door card andt he door panel. here is the morel titanium elate with the two spacer rings, note that they are profiled at certain spots to clear the gap between the door panel and the door card:
and here are the two rings after they were coated with several layers of truck bedliner:
unfortunately, with how the speaker is mounted, there was no real way to take a picture of the door panel before the speaker went on. basically, four bolts goes through the speaker, the grille, the door card, the spacer ring and bolts to the rivet nut behind it.
here are the pictures of the tweeter nets to the oem tweeter housing, again, looks very simple, but if you look closely, you will see that there is a very thin 1/8" acrylic ring that is bonded to the oem base. the reason for this is that the stock base was weakened to the point of disintegrating after all these years, already cracked and broken at various places and if we tried to actually mount the heavy piccolo tweeter to it, it probably would have dissolved . so jesse fabricated this little spacer to tie it all together and give the whole thing some integrity. it is also thin enough that the twist on oem grille can still fit and clear the tweeter dome:
here are two pictures of the wiring bundles as it travels from the front of the car to the back, sine the stock carpet is glued in place, and we had to peel it up and reglue it, there are no pics of them under the carpet