DiyMobileAudio.com Car Stereo Forum banner

1 - 11 of 11 Posts

·
Registered
Joined
·
17,758 Posts
Discussion Starter #1
Hey everyone, we're back with another build log. The videos will be coming out first, and in sections this time. They are being filmed better, with more detail, more fabrication, etc etc.. This first video is of the pillars. I would write a wall of text about what were are doing to this car, but you will hear all about it in the first few minutes of this video. Enjoy


Tesla Model S - A-Pillars pt. 1

Tesla Model S - A-Pillars pt. 2

Tesla Model S - Trunk Fabrication pt. 1

Tesla Model S - Trunk Fabrication pt. 2 & Final Walkthrough
 

·
Registered
Joined
·
17,758 Posts
Discussion Starter #2
Hey guys, we are back with another build log. This time its Ron's Tesla Model S. I met Ron a few years back at one of the northeast DIYMA get togethers. He recently purchased this Model S and of course the first thing he needed to do was upgrade the poor excuse of a "Premium" OEM sound system. We used some of his equipment that came out of his Audi, and some of it was new. What we used is as follows..

. Fiio M11 into Audison SFC (converts coaxial to optical), as well as the OEM radio
. Helix P-SIX Mk2 with Helix Director
. Zapco Z-1KD
. Audiofrog GB10
. Audiofrog GB25
. Audio Development W800NEO
. Audiofrog GB12D2
. ResoNix Sound Solutions sound deadening









First things first were the doors. We decided to use the Audio Development W800NEO to cover midbass frequencies. The OEM drivers in the Premium OEM system are 8", so fitting these isnt very hard. These were mounted on composite baffles to prevent them from deteriorating over time while also being strong and rigid enough to provide a suitable surface for such a powerful driver. The doors were treated with products ResoNix Sound Solutions. The outer door skin was treated with ResoNix CLD Squares and ResoNix Rope.









Next up were the pillars. These house Audiofrog GB10's and GB25's. There are a few design aspects that went into creating these. One of the requirements from Ron was something along the lines of "I want YOUR pillars". Essentially, he was giving me creative freedom and wanted something that looked great. Awesome, as i love getting challenged when it comes to pillars. We ended up going for an "OEM Plus" look - something that looks like it could be a factory, but is in fact one-off. We used cues from the dash and trim in the vehicle to come up with the overall shape and design, which you will see in photos below. That said, the next part of the design is on the acoustic side of things. We originally wanted to mount the drivers in a vertical arrangement, but that proved to be pretty much impossible while keeping aesthetics in check. That being said, i decided to push the drivers as far into the dash/windshield corner as much as possible. What this is doing is getting the drivers as physically close as possible to the prominent reflecting boundaries. What this does is it pushes the comb filtering as high up in frequency range as possible, and everything below that is mostly unaffected by the early reflections (in relation to the distance to said reflecting surface to X frequencies wavelength). This proved to work very well once we got to tuning the car, as there wasnt much eq required to flatten out the response. The not so obvious reason that we didnt go with OEM locations for midranges and tweeters in this car is because our experience has shown that the Tesla OEM midrange locations cause some nasty cancellation in the upper midrange. This is usually not the case in most cars, but the distance of the driver from the windshield and the shape of the windshield/dash cause a not so preferable response in the Model S that is nearly un-fixable.











Next up were the grills for the pillars. As said before, the shapes are inspired by the OEM shapes and trim in the car. What you cant really see in these photos, is the level of detail that went into these. For starters, there is a press to house a Tesla logo within the main grill which was already pressed. This is easy to spot. What isnt so easy to spot in photos is the angle of the shapes in relation to the angle of the perforations of the grill material.. they match. Not only do the angles match, but we managed to get the "lines" of the perforations to be directly on the edge of the chamfers that are on the bottom of the grill, and the outside angle of the grill. I show exactly what i mean in a photo below. Another small detail that is nearly impossible to see, is that the hole in the center of the Tesla logo that is placed on the grill is lined up perfectly with a hole in the grill. I dont even remember how many tries it took me to get these this perfect. If you look closely at the second photo, you can see the indent for the Tesla logo, which was cut on the laser and painted/engraved to match










Here you can see how i lined up the outside shape of the grill to the grill materials perforation angle, and also placed the corner of the press along two of the perforations "lines" on the bottom and outer parts.










The 12v battery is located under the hood, and we drilled/tapped the tie down bracket to secure the fuse holder.









Some of the power, speaker, and signal wire ran in the quarter panel along the OEM wire harness.








Here is the start of the 1.4 cubic foot enclosure that houses the Audiofrog GB12D2 as well as the beauty panel that finishes the trunk. The enclosure is built out of 3/4" baltic birch



 

·
Registered
Joined
·
17,758 Posts
Discussion Starter #3
Here we lasered out a test template for the carbon accents to get everything else lined up. The final pieces were lasered out of 1/4" acrylic and rounded over on the router










The pressed grill is sandwhiched between the base beauty panel and the panel you see above which is secured with threaded inserts and m5 countersunk machine screws








Wrapping the trim pieces in raw carbon fiber was a bit trickier than anticipated. In the end, im very happy with how it turned out









This was a test piece for the carbon trim. This one actually turned out pretty good, but was ultimately not used as the angle of the weave did not match the angle i wanted.








Here is the final design we settled on. Underneath the wood trim, you can see a lightly frosted acrylic layer that will be lit up. You can also see the angle of the weave on the carbon follows the middle edge of the top trim panel.








Trim pieces were wrapped in OEM matching Alcantara and the carbon trim was secured.









As said before, the ring around the sub that secured the grill is secured with machine screws. The other 4 cut outs in the vinyl in this photo are for dowels that help keep the trim panel lined up and secured









The Helix Director was installed in the cup holder area. This controls master volume, digital volume, subwoofer volume, stores presets, and more.










Money shot.. Pillars done and installed :)











Trunk finished and all trim secured



 

·
Registered
Joined
·
3,398 Posts
Fantastic work once again, Nick. Those A-pillars and the trunk are stellar. I'm sure that it sounds decent as well with the AD and Audiofrog drivers. 👍

Oh, and where you used the dowels for the trunk panels, I will typically use speaker grill panel fasteners like these from Parts Express...

Pressfit Speaker Grill Guides 1

Heavy Duty Pressfit Speaker Grill Guides

Sometimes I'll just use the male side into a hole in plastic or mdf panels if they don't need to be 100% captive. Of course you could use small Neo magnets as well if the above are too deep for the thickness of the panel.

Parts Express also have ~1" diameter flat disc types as well... similar to these...

3M Dual-Lock Reusable Fasteners 13/16" Diameter

Oh and Kirk Proffitt used some small but fancy aircraft-type twist-lock fasteners for the trunk panels in his Acura that Rob has now. Can't remember what they are called but they should still be in his build log. Very slick and "High-End".
 

·
Registered
Joined
·
17,758 Posts
Discussion Starter #5
Fantastic work once again, Nick. Those A-pillars and the trunk are stellar. I'm sure that it sounds decent as well with the AD and Audiofrog drivers. 👍

Oh, and where you used the dowels for the trunk panels, I will typically use speaker grill panel fasteners like these from Parts Express...

Pressfit Speaker Grill Guides 1

Heavy Duty Pressfit Speaker Grill Guides

Sometimes I'll just use the male side into a hole in plastic or mdf panels if they don't need to be 100% captive. Of course you could use small Neo magnets as well if the above are too deep for the thickness of the panel.

Parts Express also have ~1" diameter flat disc types as well... similar to these...

3M Dual-Lock Reusable Fasteners 13/16" Diameter

Oh and Kirk Proffitt used some small but fancy aircraft-type twist-lock fasteners for the trunk panels in his Acura that Rob has now. Can't remember what they are called but they should still be in his build log. Very slick and "High-End".
Thank you. As far as the trunk panels, truth is, those speaker grill clips kinda... suck lol. Try a 1/4" dowel and a 1/4" drill bit, some CA glue, and some sand paper. Much stronger, wont break as easy, etc etc
 

·
Premium Member
Joined
·
1,442 Posts
I have a question about the fiio to audison. What's the point of it if you can just go from fiio straight into the dsp? Reason I ask is because I'm doing my truck the same way. Fiio straight into the dsp coax or spdif. whatever mine has
 

·
Registered
Joined
·
3,676 Posts
Awesome install and attention to detail Nick!!!

Sent from my Pixel 4 XL using Tapatalk
 

·
Registered
Joined
·
3,676 Posts
I have a question about the fiio to audison. What's the point of it if you can just go from fiio straight into the dsp? Reason I ask is because I'm doing my truck the same way. Fiio straight into the dsp coax or spdif. whatever mine has
I think he wanted to integrate the stock car audio system in to helix dsp. So he could still hear everything about the car and switch between the source.. this will be my only advance of the unit..

Sent from my Pixel 4 XL using Tapatalk
 

·
Premium Member
Joined
·
1,442 Posts
I think he wanted to integrate the stock car audio system in to helix dsp. So he could still hear everything about the car and switch between the source.. this will be my only advance of the unit..

Sent from my Pixel 4 XL using Tapatalk
I missed the part that said "and oem audio" I see the reasoning now. At first I thought the fiio was the only source unit

Sent from my SM-G975U using Tapatalk
 
1 - 11 of 11 Posts
Top