All Done

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

2 #8 mounting screws included (not shown)

Primer used

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

Corners Welded and Ground

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

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

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

Grill Pattern

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

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