might be too late but I have the top half of the factory speaker pods on hand if you decide to change directions. maybe you can mod some lower halves with the fiberglass work.
Its too late, but thanks for the offer. Maybe Bam could benefit from them since he hasnt started yet.
Took the weekend, working on and off around family activities. Plus I havent done much custom molding before, so I did many small steps whereas the pros may have combined into one. After getting this far, it wasnt that hard and will be a confidence springboard into my next custom task. Just gotta wait for my Braille battery to show up this week :encouragement:
Got the drivers side installed. Gonna have to wait on the passengers side because I have some more wiring and things to do and need to keep the panel off for a bit. Here is how the drivers side looks:
UPDATE with MORE PICS! TASK #2. MOUNTING 10" SUB INTO SPARE TIRE BAY
So I decided to put the exclamation point on the final step in enhancing the musical sound of the wagon.
I took the challenge to expand upon my previous fiberglass molding skills and attempted to design a custom 10" sub enclosure using the spare tire bay.
I still wanted to be able to use the full capacity of the hatch space, whether or not the rear seats were folded down, and still have some tasteful sounding bass.
After much research, measurements and air space calculations, I came up with a design that utilized the spare tire bay. I plan to keep the stock jack and tool bag in its original location. I have some JDM roof rails that I will eventually install, with a basket to hold the factory spare donut.
Layered spare tire bay with heavy duty, non-stick foil and applied fiberglass mat and resin:
I plan on putting in a different flooring material and counter sinking sub in the box, so used a laser level to make sure i trimmed the fiberglass mold at the right height.
Base trimmed to height:
Making the top out of 1/2" plywood. I ended up beveling the edges so it will fit inside the walls of the fiberglass base.
Cutting rings for speaker in order for it to be countersunk for full clearance:
Attaching plywood top to fiberglass bottom using bondo. Will seal it up from the inside too:
As the box sits after fiberglass, bondo, caulk and sanding:
Finished:
Until I can decide on final mount method for the box and get the new hatch floor installed, Im using a moving blanket to keep box from vibrating and to cover up the sub from nosey passersby.
Task #3 will be doing the final mounting of the Braille Battery. I will post pics of that install in the next few days so stay tuned.
Nice! I like the detail and finish you put in. I'm thinking of two different approaches though one is similar. Either is a ways off financially and therefore chronologically, lol!
Nice! I like the detail and finish you put in. I'm thinking of two different approaches though one is similar. Either is a ways off financially and therefore chronologically, lol!
Thanks! Yeah, I know what you mean. Been stockpiling and researching lots of stuff for months planning for the best way to make improvements. Still have a few things to do, but Im def happy with the results so far!
I will be going from 60lbs and 950 cold cranking amps down to 15lbs and 685 CCA (which is more than the advertised 574). Also not to mention the space/size savings and all in a truly sealed, maintenance-free battery.
Started off by making a small base plate and upper ring to help secure the battery once its in place
With a little trimming of the OEM body panel, she fits perfectly in the right rear pocket space.
Reran existing 1.0 gauge power/ground and new amp wires under the right side panel and made connections. Had to make some additional relief cuts in the panel for the wiring. I was unable to use the upper wood ring, but custom cuts and plastic panel will help hold it all down for now. I will put some finishing trim touches on it all when I finish replacing the flooring material.
...And the final weigh in...
original battery: 60lbs
new braille B2015: 15lbs
sub and enclosure: 20lbs
rear 6x9 and pods: 8lbs TOTAL: 43lbs
I was able to add a new battery, my rear 6x9s and sub in custom enclosures and still have a 17 lbs to play with from the original setup when I bought the car. :encouragement: Hopefully the new flooring design (Task 4) wont eat up those 17 lbs.
Gonna try to get that completed within the next few weeks. All depends on family weekend activities.
i wish i knew how to do fiberglass work like this.. id love to have a sub box like this but i want two 10's lol
Brian, its all doable. Just do research, read other forums/articles and get plenty of supplies and take your time. Ive repaired a fiberglass boat before but had neverr done any custom molding like this before. I think t he trunk enclosure was easier than the 6x9 pods, but doubt there would be enuff airspace for 2 10" subs. It would be pushing it if you used the whole spare tire bay, removed the jack bracket and didnt countersink subs. U Just gotta do the math.
Glad u enjoy the build. Ive got more to do over time. Good luck on your beast too. It looks great!
Brian, its all doable. Just do research, read other forums/articles and get plenty of supplies and take your time. Ive repaired a fiberglass boat before but had neverr done any custom molding like this before. I think t he trunk enclosure was easier than the 6x9 pods, but doubt there would be enuff airspace for 2 10" subs. It would be pushing it if you used the whole spare tire bay, removed the jack bracket and didnt countersink subs. U Just gotta do the math.
Glad u enjoy the build. Ive got more to do over time. Good luck on your beast too. It looks great!
yeah i didnt think it would fit, i just need to find a nice box thats subtle and doesnt take up alot of room in the trunk as well as a place to hide the amp besides the back of the box..
thanks man, theres going to be a hault on my build though since im having problems with my house i own in CA and its draining my pocket (had to sell parts and the volks :dispirited: ) but itll be back up soon..
and i will be watching this thread closely! :loyal:
I'm surprised have not seen you running round Woodstock.
I'm pretty much always in mine.
SERIOUSLY! There have been reported sightings of yours (KSU, Woodstock Home Depot) but I have never "actually" seen you either. I will be driving mine more now that Ive got some of the kinks worked out of it, but usually in the afternoons (after 4pm) and on the weekends around the bells ferry/92, hwy 5 to towne lake area.
We are always in it, well except for lately due to AC Compressor took a shit.
I'm all over woodstock in it.
I can relate, no AC in mine when I bought it. Will try and work on getting parts to install AC sometime this winter. At least its cooling off and my heater works! I mentioned to Bam that we should try and get a Sat or Sun afternoon meet later this fall/early winter after his to-do list gets a little shorter....mine too!
Ill continue to keep an eye peeled for ya during my local outtings. :onthego:
Well its been too long without any updates. I have a lot going on around the house and with family life, but been throwing around ideas for a wooden floor for the wagon and tinkering when I could over the past few weeks.
I actually make wooden baseball bats as a hobby in my spare time (at least before purchasing the wagon) and while I was at a local lumber yard, I ran across some rough cut ash to use as a floor for the back of the wagon. I got it all home, layed out and squared up using the table saw. Cut enough to do the floor and the back of the seats, in hopes that it all will line up when the seats are folded down.
Here it all is cut and layed out.
Gonna cut tongue and groove in order to hook it all together.
Creating Tongue and Groove
All glued up:
Used stock carpet for pattern
Using the OEM tire bay cover for support and contour fitment.
Attaching the piano hinge to lid for flip up access. This is the view from the underside:
Installed for a final test fit with working hinge
Before Stain:
After sanding and a few coats of stain:
This is what I had in mind when I started, but after considering the significant amount of trimming to allow for the seats to fold back up would create waaay too big of a gap for my taste. That being said, I think I will probably just go with the stock carpet on the back of the seats for now.
More updates on the final look forthcoming *hopefully* during this next week.
Here are the final pics of the hatch floor.
I will still get plugs for the (2) 10mm bolt mounting holes up near the seat backs. Sorry for the glare in some of the pics.
Undercover Beats
Final battery install
...And the final, final weigh in...
Original battery: 60lbs
New braille B2015: 15lbs
Sub and enclosure: 20lbs
Rear 6x9 and pods: 8lbs
Ash flooring: 22lbs TOTAL: 65lbs
5 additional pounds, but considering the upgrades and overall look I think it was well worth it!:cool:
Other upgrades floating around in my head is to eventually fabricate some cup holders and install the JDM roof rails I already have.
Ive been searching many threads on info on rails and racks. If anybody has some close up photos of the stock rail mounting positions and what baskets fit on JDM rails, send em to me or lmk the locations. In the meantime, I will continue to search.
Thanks in advance for any specific info! :encouragement:
Looks utterly amazing. Are you still going to add the wood flooring to the back of the rear seats?
I probably will try in the near future, especially considering I've already cut the planks, but I think the gap between the transition to allow seats to fold up are going to be too big and look dumb. Thanks for the props and Stay tuned!
Other upgrades floating around in my head is to eventually fabricate some cup holders and install the JDM roof rails I already have.
Ive been searching many threads on info on rails and racks. If anybody has some close up photos of the stock rail mounting positions and what baskets fit on JDM rails, send em to me or lmk the locations. In the meantime, I will continue to search.
Thanks in advance for any specific info!
Nice finishing touches!
bam-bam's done several installs of roof rails; check out the build logs for 'cnote civic', 'Pebble's resto' and the 'wagocamper'.
Nice finishing touches!
bam-bam's done several installs of roof rails; check out the build logs for 'cnote civic', 'Pebble's resto' and the 'wagocamper'.
I will check them all out again, but didnt think he had installed the JDM type, always something salvaged. I just was curious on the oem mounting demensions, as the more i looked to find a good picture of them, never could. Just curious how tight to the roof gutters and how far fwd they were mounted from factory. In the end, it wont really matter. :encouragement:
I will check them all out again, but didnt think he had installed the JDM type, always something salvaged. I just was curious on the oem mounting demensions, as the more i looked to find a good picture of them, never could. Just curious how tight to the roof gutters and how far fwd they were mounted from factory. In the end, it wont really matter. :encouragement:
You're right, of course, I was thinking of the luggage racks offered in the US. I don't know anything about the JDM racks. All the racks, indeed all the things we think of as options, were dealer installed extras. Even A/C, stereos, pax side wing mirrors, etc.
Do you have any pictures of your JDM rack?
This is all I got for now. All you Overseaers that maybe reading this, I forgot that I need the end caps to cover the bolt holes. If you have these or can get them, PM me.
Comments
Its too late, but thanks for the offer. Maybe Bam could benefit from them since he hasnt started yet.
Its an 03 Pathfinder
TASK #2. MOUNTING 10" SUB INTO SPARE TIRE BAY
So I decided to put the exclamation point on the final step in enhancing the musical sound of the wagon.
I took the challenge to expand upon my previous fiberglass molding skills and attempted to design a custom 10" sub enclosure using the spare tire bay.
I still wanted to be able to use the full capacity of the hatch space, whether or not the rear seats were folded down, and still have some tasteful sounding bass.
After much research, measurements and air space calculations, I came up with a design that utilized the spare tire bay. I plan to keep the stock jack and tool bag in its original location. I have some JDM roof rails that I will eventually install, with a basket to hold the factory spare donut.
Layered spare tire bay with heavy duty, non-stick foil and applied fiberglass mat and resin:
I plan on putting in a different flooring material and counter sinking sub in the box, so used a laser level to make sure i trimmed the fiberglass mold at the right height.
Base trimmed to height:
Making the top out of 1/2" plywood. I ended up beveling the edges so it will fit inside the walls of the fiberglass base.
Cutting rings for speaker in order for it to be countersunk for full clearance:
Attaching plywood top to fiberglass bottom using bondo. Will seal it up from the inside too:
As the box sits after fiberglass, bondo, caulk and sanding:
Finished:
Until I can decide on final mount method for the box and get the new hatch floor installed, Im using a moving blanket to keep box from vibrating and to cover up the sub from nosey passersby.
Task #3 will be doing the final mounting of the Braille Battery. I will post pics of that install in the next few days so stay tuned.
Thanks! Yeah, I know what you mean. Been stockpiling and researching lots of stuff for months planning for the best way to make improvements. Still have a few things to do, but Im def happy with the results so far!
I will be going from 60lbs and 950 cold cranking amps down to 15lbs and 685 CCA (which is more than the advertised 574). Also not to mention the space/size savings and all in a truly sealed, maintenance-free battery.
Started off by making a small base plate and upper ring to help secure the battery once its in place
With a little trimming of the OEM body panel, she fits perfectly in the right rear pocket space.
Reran existing 1.0 gauge power/ground and new amp wires under the right side panel and made connections. Had to make some additional relief cuts in the panel for the wiring. I was unable to use the upper wood ring, but custom cuts and plastic panel will help hold it all down for now. I will put some finishing trim touches on it all when I finish replacing the flooring material.
...And the final weigh in...
original battery: 60lbs
new braille B2015: 15lbs
sub and enclosure: 20lbs
rear 6x9 and pods: 8lbs
TOTAL: 43lbs
I was able to add a new battery, my rear 6x9s and sub in custom enclosures and still have a 17 lbs to play with from the original setup when I bought the car. :encouragement: Hopefully the new flooring design (Task 4) wont eat up those 17 lbs.
Gonna try to get that completed within the next few weeks. All depends on family weekend activities.
i wish i knew how to do fiberglass work like this.. id love to have a sub box like this but i want two 10's lol
Brian, its all doable. Just do research, read other forums/articles and get plenty of supplies and take your time. Ive repaired a fiberglass boat before but had neverr done any custom molding like this before. I think t he trunk enclosure was easier than the 6x9 pods, but doubt there would be enuff airspace for 2 10" subs. It would be pushing it if you used the whole spare tire bay, removed the jack bracket and didnt countersink subs. U Just gotta do the math.
Glad u enjoy the build. Ive got more to do over time. Good luck on your beast too. It looks great!
yeah i didnt think it would fit, i just need to find a nice box thats subtle and doesnt take up alot of room in the trunk as well as a place to hide the amp besides the back of the box..
thanks man, theres going to be a hault on my build though since im having problems with my house i own in CA and its draining my pocket (had to sell parts and the volks :dispirited: ) but itll be back up soon..
and i will be watching this thread closely! :loyal:
I'm surprised have not seen you running round Woodstock.
I'm pretty much always in mine.
SERIOUSLY! There have been reported sightings of yours (KSU, Woodstock Home Depot) but I have never "actually" seen you either. I will be driving mine more now that Ive got some of the kinks worked out of it, but usually in the afternoons (after 4pm) and on the weekends around the bells ferry/92, hwy 5 to towne lake area.
It was purchased as the parts hauler, it has morphed into the family truckster kind of thing.
We are always in it, well except for lately due to AC Compressor took a shit.
I'm all over woodstock in it.
I can relate, no AC in mine when I bought it. Will try and work on getting parts to install AC sometime this winter. At least its cooling off and my heater works! I mentioned to Bam that we should try and get a Sat or Sun afternoon meet later this fall/early winter after his to-do list gets a little shorter....mine too!
Ill continue to keep an eye peeled for ya during my local outtings. :onthego:
Well its been too long without any updates. I have a lot going on around the house and with family life, but been throwing around ideas for a wooden floor for the wagon and tinkering when I could over the past few weeks.
I actually make wooden baseball bats as a hobby in my spare time (at least before purchasing the wagon) and while I was at a local lumber yard, I ran across some rough cut ash to use as a floor for the back of the wagon. I got it all home, layed out and squared up using the table saw. Cut enough to do the floor and the back of the seats, in hopes that it all will line up when the seats are folded down.
Here it all is cut and layed out.
Gonna cut tongue and groove in order to hook it all together.
Creating Tongue and Groove
All glued up:
Used stock carpet for pattern
Using the OEM tire bay cover for support and contour fitment.
Attaching the piano hinge to lid for flip up access. This is the view from the underside:
Installed for a final test fit with working hinge
Before Stain:
After sanding and a few coats of stain:
This is what I had in mind when I started, but after considering the significant amount of trimming to allow for the seats to fold back up would create waaay too big of a gap for my taste. That being said, I think I will probably just go with the stock carpet on the back of the seats for now.
More updates on the final look forthcoming *hopefully* during this next week.
looks amazing.
Here are the final pics of the hatch floor.
I will still get plugs for the (2) 10mm bolt mounting holes up near the seat backs. Sorry for the glare in some of the pics.
Undercover Beats
Final battery install
...And the final, final weigh in...
Original battery: 60lbs
New braille B2015: 15lbs
Sub and enclosure: 20lbs
Rear 6x9 and pods: 8lbs
Ash flooring: 22lbs
TOTAL: 65lbs
5 additional pounds, but considering the upgrades and overall look I think it was well worth it!:cool:
Other upgrades floating around in my head is to eventually fabricate some cup holders and install the JDM roof rails I already have.
Ive been searching many threads on info on rails and racks. If anybody has some close up photos of the stock rail mounting positions and what baskets fit on JDM rails, send em to me or lmk the locations. In the meantime, I will continue to search.
Thanks in advance for any specific info! :encouragement:
I probably will try in the near future, especially considering I've already cut the planks, but I think the gap between the transition to allow seats to fold up are going to be too big and look dumb. Thanks for the props and Stay tuned!
bam-bam's done several installs of roof rails; check out the build logs for 'cnote civic', 'Pebble's resto' and the 'wagocamper'.
Do you have any pictures of your JDM rack?
This is all I got for now. All you Overseaers that maybe reading this, I forgot that I need the end caps to cover the bolt holes. If you have these or can get them, PM me.