Hey guys, I have 3 general questions before I start my project.

I want to build custom door panel enclosures for my 99 Alero. First of all, I know you all are going to say "put them things in your kick panels instead," but for a multitude of reasons (including the fact that I already ripped off my part of my door) I am going to go with door panel enclosures. My next car will be kick panels almost for sure.

1.) Short strand vs. long strand fiberglass:
It is my first time using fiberglass for anything and I have no idea what to expect so I bought a small can (1 kg) of short strand Bondo-Glass fiberglass to experiment with. Should I go for the long strand version (for greater strength) or will short strand suffice?

2.) Will 9 litres be enough space for 6.5" components:
I plan on making a total sealed enclosure, but I can only get around 9 litres of total volume from my calculations. If kick panel enclosures are supposed to be so great, then how in the world do they do it with only maybe a litre or so of internal enclosure volume? I haven't bought the speakers yet, but am looking at a few different ones right now. Either way, similar specs on all of them call for around 15 - 20 litres internal volume for sealed enclosure.

3.) How the heck to fasten it to the door:
See picture below. I have no idea how I'm gonna do this

 

very easy to make a door pod for that door.

first, cut a piece of 1/4 MDF to fit over the shape of the small holes on the door panel. mount a couple 2x4's or something of that nature on the back for support.


Then, cut out a ring for your speaker, and if your using components, also cut a small ring for the tweeter. Round the outside edges with a router. Mount the rings for the speaker and tweeter on the board that goes on the door using small sticks of wood, and a nail gun or glue at the angle that you want them to be.

After your happy with the direction that your speaker will be pointing, stretch cloth tightly over the front and staple it on the back, hot glue will also work, but won't hold as well as staples.


After the fabric is stetched, use fiberglass resin, and soak the cloth, this will give you a nice smooth shape. After first coat of resin is dry, then you can start fiber glassing a couple layers one the pod, don't use bondo glass, it's not very stong, use fiber glass and resin. When figerglassing the pod, try to glass the inside as much as you can, it'll save you alot of sanding in the end. Once you glass a couple layers on the pod, and it is good and strong, use a quility bondo and bondo the outside of the pod, sand smooth, repeat if needed. When glassing is finished you can remove the 2x4's, or whatever you used, replace the pieces you cut out, glass the cut out pieces on booth sides for strenght. Once you are satisfied with the surface, spray with scratch fill primer. You can accually get it in a can at Canadian Tire, then paint. or if your not painting the pods, vynle them.

hope this makes sense, keep asking questions if you need help.

 

Wow, those were great instructions! Thank you very much. I will begin my project this weekend, now that I know how to start. Much appreciated.

 

post pics of the process if you can, and ask questions along the way if you get stuck with something

 

I just done this exact same thing on my cutlass a month ago..

here are some pics of the build.. they are 3/4 finished - once i did a test mount on the doors and in the car I was so happy with the difference in sound i havn't finished them yet..

 

post number #2 with more pics

 

To answer your questions..

1) Neither short or long.. I used just an old T Shirt, and fibreglass resin.. to stiffen up the long open areas just use peices of fibreglass sheeting.. I bought a meter squared from Canadian Tire for 7 bucks off a roll..

2) How many pair of 6.5's you wanna put in there? sealed i guess 2 litre tops before speaker displacement for one enclosure with 1 6.5 in it. Always see if the manufacture has a recommended size. Kick Panel enclosures do so well because they are further away from your ear.. and more easy to aim for your front stage.. in my case my e brake was in the way on the drivers side - this is why i built out my doors..

3) I fastened mine using 1/2" wood screws.. tiny little brass ones from the back side of the door panel.. i suggest pre drilling the holes and use as many as you can.. in your case you may want to make some backing plating (1/32" sheet metal (the kind used in flashing works well) cut about 1/2-3/4" squares with a whole in the center - similar to a washer. I find washers never come big enough and the sheet metal can be trimmed easily)

 

scroud, wow, yer post is almost sticky worthy . It helped me too, thanx.

 

What kind of material would you be using to cover the pods? Right now, I am doing something very similar and require some guidance regarding the covering. Ideally, I would like something that gives the look of leather however it must be able to stretch and conform to all the contours...Suggestions???