Kickpanel Speaker Project*PICS*-updating all week till done!

[jakeslim]

Ok, as I noted in an earlier post, I started making my new speaker kickpanels as
mentioned on other post here in past. I bought one panel board at hardware store for about $5.00. Also bought a gallon of fiberglass resin for about $30, but you could get buy with a much smaller amount

1) Pic shows the panel cut, with raised "o" for speak, angled with various post length.

Old T-shirt does the job..ruined with work on truck


2) In first pic, the "O" is already glued to t-shirt. Now to glue the shirt to frame of kickpanel. Buy a cheap $4.99 glue gun at HF..easy and cheap.

Starting the glueing process. Work around, making sure it is smooth and tight( )Glue points at a time, not with a constant bead, that way you can adjust and take your time.

All done with Glue! Notice that I brought done the section that will have the vent lever secured to it so that there is no interference. You can see the glue line that makes this happen.




Each day this week, I'll be adding to post as I progress. Goal is to finish for a Saturday installation!

[jakeslim]

3) (the next pics are of the drivers side. I set the speaker lower to allow room for ebrake, vent lever and highbeam switch. )
Now, for a coat of resin. Based on my readings, i need one coat of pure resin, then two coats of resin with fiberglass mat cloth. This is just with the first coat of resin.

Notice the crease on back side of enclosure. This is the slack t-shirt that I folded and set. Its hard now and nothing a little bondo won't cover, and its on the back side out of sight!

Notice that I resined all the way over the ring to ensure good seal. I did this based on posted directions that I've read


MORE TO COME TOMORROW

[LUV2XCLR8]

WOW

[raggedjim]

Nice work, I may try this...

Rg

[FormerMember]

Hmn, I may have to do this...

[GMC71k20]

how do you get the fiberglass to come in contact with the panel board? do you cut away at the fabric? thanks, bob

[jakeslim]

Originally Posted by GMC71k20

how do you get the fiberglass to come in contact with the panel board? do you cut away at the fabric? thanks, bob

Since the Tshirt is porous, the resin bonds with the shirt to the panel on near and on edges. Seems like a nice tight bond. Tonight i'll post pics when I resin the passenger side. Also, I'll be adding the second layer to the driverside.
The trick would be to use porous fabric so the resin can soak through easily since it's fairly thick.
This is my first time doing this also, so I'll try to provide the headaches that I encounter also...none yet though.

[Jimmy72custom]

Looking good!

[jakeslim]

Ok, Tuesday evening process. This took me about 20 minutes to do, both passenger and driver side.

This is the passenger side. I gave it a first coat of resin only.


Next is the driver side. This is the second coat and I used small pieces(4" by 6" or so) of fiberglass mat cloth. I just laid it down where I wanted it and with a paintbrush, thoroughly covered with resin until cloth was completely wet.


This pic is with both driver and passenger kick panels. The angles are the same, but the driver side is set lower to accomodate the ebrake. The driver side now has the two coats, one resin(let dry) then resin and fiberglass mat. The passenger side has one coat of resin and is wet.


Tomorrow night, I'll throw a third coat on the driver side, and a second on the
passenger side. I should be ready to cover by Friday with material of choice. I have not decided on carpet or black vinyl.....

[phantom dually]

Looks messy!! The resin, not you work!!

[70short/step]

You are making it Look Way to easy!!

[BobbyK]

Great pic's man!Thanks for the tutorial.
Keep it coming!

[jakeslim]

No pics from last night, long day at work so too tired. I'll have more done tonight and pics

[raggedjim]

Jake, don't let us hurry you, take your time, you're doing a great job.

I appreciate the pics, Rg

[vtblazer]

What size speaker will you be running?

Thanks for the "how to"

[jakeslim]

I picked up some 4" infinity speakers that were 40% off. They should sound nice. I'm off work today so after I get back from the DMV, I'll post more pics

[RunTMCfan]

Good job. I've been into car audio very heavily since about 92'. Your work looks good and far exceeds many 1st time attempts that I've witnessed.

Next time try Speaker grill cloth to wrap the enclosure. It stretches much better. You then load the cloth only with resin. Once cured add the mat until you can stand on it.

Once again great work.

Robk

[jakeslim]

Originally Posted by RunTMCfan

Good job. I've been into car audio very heavily since about 92'. Your work looks good and far exceeds many 1st time attempts that I've witnessed.

Next time try Speaker grill cloth to wrap the enclosure. It stretches much better. You then load the cloth only with resin. Once cured add the mat until you can stand on it.

Once again great work.

Robk

Thanks. The idea was to go cheap , hence the t-shirt . I first coat i put down was just resin, the second/third was with mat
I just finished the passenger side today and second resin/mat coat on the driver side. Too much fun Where are the PICS?!?coming, camera battery is charging

Correction to speakers size in earlier post, they are Infinity 5 1/4" speakers, not 4".

[LUV2XCLR8]

Are you gonna be selling these? at discounted board members pricing of course

[jakeslim]

Ok, as mentioned..i put the first mat/resin coat on the passenger side, and a second mat/resin coat on the drivers side. With the fibermat, the enclosure is VERY strong and solid.
So I set out in sun and dried pretty quick, at least enough to test fit

Driver side with the soon to be speaker

Now, in the truck, pedal and vent lever clear nicely

A different perpective with my shoes


Passenger side with speaker(test fit)


In truck...why is you head turned sideways?


One thing, they are not fully set in place, so nevermind the if they look off on edges, I just placed them easy for now. I am going to install them with some silicone glue once ready

Tomorrow, final coats in early morning,sun, cloth/cover late in day

[FRENCHBLUE72]

This is something I have been wanting to do maybe I should add this to my very very long list of things to do..

[RunTMCfan]

This does take some of the personal touch out of it, but you could buy some plastic kick panels and use them as a platform for the mold. You know...like the ones in the catelogs. If you are willing to cut into the metal of the kick panel you could recess the speaker just a bit and go a little more low pro on the size/depth of the mold.

Rob

[jakeslim]

Originally Posted by RunTMCfan

This does take some of the personal touch out of it, but you could buy some plastic kick panels and use them as a platform for the mold. You know...like the ones in the catelogs. If you are willing to cut into the metal of the kick panel you could recess the speaker just a bit and go a little more low pro on the size/depth of the mold.

Rob

No cutting allowed! Cutting metal on these old trucks is a no-no for resale value . Buying the plastic ones at $70+ bucks defeats the purpose in my eyes, kinda like paying someone to change my spark plugs . This project was so easy and I am terrible at this kind of stuff(wood/craft/kinda stuff). I would recommend this for all even just thinking about it,but not sure.

[jakeslim]

Update- Well I've finished covering and installing the kick panels. Pics later today.
I lined the inside of the panels with Fatmat, then bought $5.00 worth of black material at the local craft store(took my girlfriend for support ).
Installed my cd changer, Sirius unit, head unit(last week), and the panels. Sounds excellent. I think the fatmat i lined inside the kickpanels kills any kind of
noise "twang" or vibrations. The tweeter is crisp and lows tight.

[LUV2XCLR8]