Thursday, March 13, 2014

All Done


 Two speakers and 48" cord terminated in a 2 pole trailer connector

2 #8 mounting screws included (not shown)

Primer used


Monday, February 24, 2014

Filling and Adapter


 Applying Bondo

 Bondo didn't harden so I applied JB Epoxy

 Installing the speaker mounting studs

 As expected, the studs warped the adapter panel

 Test fitting the adapter

 Adapter painted


 Adapter with felt cloth to reduce metal to metal noise and hide speakers



Friday, February 21, 2014

Corners Welded and Ground

Next step is to apply plenty bondo and sanding. Also need to make the speaker adapter plate.














Thursday, February 20, 2014

Grill Welded, Studs Installed, & Form Pressed


Ready to weld

Tack welded

Done welding

Installing the studs


 Sheet metal sandwich


Starting the pressing





 Got a little crooked

 Just repositioned the press ram to straightened out

Sides formed
 
 Sides clamped for corner forming and welding




Wednesday, February 19, 2014

Template & Sheet Metal



 Template marked and cut out

Template taped to the sheet metal
 
 Sheet metal marked and hole locations punched for the speaker mounting in the case and the case mounting to the kick panel


 Sheet metal cut out and grill fitted

 Press ram

 Press form

Test setup of the press

Tuesday, February 18, 2014

Grill Pattern

Comparision of the old vs new grill. Hole patterns are different because the new grill has a hight open percentage.



Wednesday, February 12, 2014

Restart!

Decided to build only one box and make it substantially similar to the original. Will be scrapping the 6" speaker and use two smaller speakers to help keep the depth down. One thing I have not done was to use press in studs called PEM studs. With the proper anvil and carefully drilled holes a 5 ton press is used to "cold flow" the base metal into the stud securing groove.

Here is an animation of how it is done: http://www.pemnet.com/design_info/video_library_fh_test.html

I bought some 3/4" round bar made from A2 steel to make the anvils from.

 Bottom anvil, top anvil, PEM stud, test piece of sheet metal, and a couple of spacer nuts.

PEM stud seated in the sheet metal on top of the bottom anvil
 
 Just before pressing

 Pressed

PEM fully seated
 
Bottom side
 
Completely flush on both sides

Friday, January 17, 2014

Speaker Spacer Ring


 Painters tape, score with calipers, score with hack saw

Cutting through
 
 1.25" chunk removed

Using SS banding tape to close the ends
 
 Heating the spacer with heat gun

 After cooling ends hold together and align

 Ends glued

Fits perfectly