2011 Chevrolet "Mayhem"

[mikelbolton]

OK guys,

the system has grown up a little.

We started by searching for a new setup, ended up designing the enclosure in Sketchup.

After the design was taken care of, we began removing the old setup.

Then we began cutting the new enclosure.

Of course, I couldn't have done it without my little helper.

Test fitting, double checking box height, baffle size, and seat slope.

By this point I was realizing that the rear cargo latches would need to be removed.

Clamping everything together. Gotta sand everything and get nice clean lines. (still had to figure out backwall angles and make final cuts.

Got the hardware together for final assembly.

Love these screws, no predrilling!!!!

My loving girlfriend, laying out the baffles so I can make my cuts for the port.

Figuring out the port was probably the hardest and most frustrating part of this build. I went through a few design changes, but finally settled on one that I'm more than happy with. Dealing with the limited space of this hatchback, I made the port 1-common wall, and the front of the port extends over across the enclosure and serves as the amp rack.

[mikelbolton]

Here, I was testing the lines of the port, making sure everything lined up.

The inside port will need to be painted before assembling it, or placing it into the baffle. For this we have chosen metallic blue paint.

Base coat of black

Second coat is a silver, which adds a "flake" to the blue metallic (these are rattle cans).

The last coat is the metallic blue.

[mikelbolton]

The paint had to be taped over to protect it during the rest of the install. Test fitting the port into the baffle again.

Giving myself a little visual motivation.

[mikelbolton]

Next step was notching out the baffles. Here's one of the baffles notched out.

Now that we've gotten this far, time to glue and screw in the first baffle. Notice, the block sitting under the amp rack, it's allotting space for the second baffle. Don't notice my shop, it is in dire need of a serious cleaning, but that's after this project ;-)

I used the battery to hold down the port while the glue dried.

[mikelbolton]

Got a few goodies in.

Hydraulic crimps!

Battery Terminals

[mikelbolton]

Knukonceptz Kollosus 1/0

Tsunami 200 Amp Circuit Breakers

[SMZ2]

Looking good man! I like the amp rack a lot!

[mikelbolton]

Can't forget the security screws and T-nuts for the sub and amp rack!!!

Couldn't spring for a new system and not have it setup right... A slightly used DD-1

Time to get back to work!

Cheap Chinese voltage gauge.

It was only two-wire, so had to wire it to a relay.

[mikelbolton]

Initially, had it located on dash.

I began to dislike the location, so moved it up onto the pillar.

Time for wiring

[mikelbolton]

Out with the old.

In with the new.