A fellow board member asked me to build him dash pods for his Honda. So today I picked up some supplies and made the pods as requested. These are pretty big compared to other pods I've made, but the way I build them is pretty much the same. There are other ways to build them of course.

This time around I started with foam ***** I picked up from Michalle's. I cut the ***** in half or so depending on the shape I want and the size I need.

I then make the MDF rings to fit the speakers being used. These particular speakers have mountind tabs, which is the reason they are so big. You can make the rings from other mateiral like aluminum, but MDF was requested on this project.

Relief cuts were made in the back side of the rings to allow for better air movement around the speakers basket. "T" nuts were also added as the fastening method for the speakers.

The rings are then attached to the foam and I wrap them with fleece. Staples keep the fleece in place and Fiberglas resin strengthens it. I also add reinforcing fiberglass to the outside of the pods and sand them.

To sand the units I make a ring the exactly fints into the pod and put in on a drill to act like a lathe. This makes the work go much faster. Bondo is added last to fill in any small pits and make the pods smooth.

The inside of the pods also get reinforcing fiberglass. But I also add lead wights for mass.

I will post how I mount these pods in a week or so. I will also covering them with flocking to make a seamless finished product. And finally I will show how I make the grills.

 

I look forward to seeing the rest of the build process!

 

i like what i see so far. definatly keep us posted

 

I'm glad someone is good at doing stuff like this, because I'm not.

 

4th picture in looks like earth in about 10 years.. very dark and eery.. haha.. good job man it looks wicked so far !

 

You work for Samuel, or just have one of their hats?

The place I work was purchased by Samuel middle of last year. I work at Samuel Metal Blanking, used to be called Namasco.

Saw the torch there in that one pic.

These look really cool. Where/how will the be implemented into this guys vehicle?
Where do you get all the necessary supplies for fibreglassing? I just finished up a sealed enclosure yesterday, and would like to try my hand at fibreglassing the outside of the box, strictly for cosmetic purposes and to see if I can do it.

 

Yup, I work for Samuel. I'm a sales rep.

The speakers being used here are made by Canton.

The owner of the car wants to put these up on the dash, but they are pretty big, so I will leave that decision to him. They would work well in the kicks as well.

 

Here are the grills.

I made them with MDF and a router. I can list the setp I took on this, but I think it's pretty straight forward.