2015 Chevy Sonic/Wall/4 PSI 15's/SA 6K/Active/Arc/CDT/Singer/US Alt/XS

[WalledSonic]

41 minutes ago, ShadeTreeMechanic said:

Pods look killer! Are you going to leave the back of the pod open to the door or is there going to be a back panel? Tuned in for more.

Yes sir.  I'll be sealing off and porting the door the best I can so I can get some midbass out of these drivers.  If I'm banging with the windows down I'll likely cut around 100Hz, but if I'm chillin with the windows up I'll probably cut at 80Hz.  I'm trying to build per these instructions from the website (obviously doubled since I have two per door):

"0.8 cubic foot with 3" diameter vent by 7" long for an f3 of 50Hz"

[nkrell11]

I'm interest to see how you seal around the pod to the door assuming either filler or some glass but maybe I'm wrong. This has me thinking about some crazy kerfing to get all the 8's in my doors.

[WalledSonic]

A lots been done recently, but nothing completely. 

Started hacking away at the passenger side pod

Close cuts for the pods

Fitted up with the door closed

Here's how close this fitment is... Maybe a quarter inch total after cone excursion:

And on the inside, maybe another quarter inch:

Started the drivers side pod

Tracing the inside edge to the door so I can figure out mounting

Final profile after cuts.  The happy lil mistake was filled with PL

[WalledSonic]

Going from (1) 6.5" in each door to (2) 8" per door:

Side profile difference:

VC Ø, spider, cone, etc for the CDT 6.5"

VC Ø, spider, cone, etc for the Silver Flute 8"

 

 

[WalledSonic]

Second set of tweets arrived

 

[WalledSonic]

Got a drive end bracket for a GM Large Case Hairpin.  

Im trying to figure out how to mount this housing in the stock location, but there are some ups and downs when it comes to the design.

The stock hole-to-hole distance is about the same.  Close enough to get bolts installed.

Its also concentric when the holes are lined up.  The Hairpin is (obv) a larger diameter than my current alt case, but the holes and pulley line up well.

Problem is that my stock alt case mounts like this: 

I would have to hog off a huge chunk of the 'feet' to match my stock alt fitment.  Unfortunately, the case is made of aluminum and Hairpins are mounted from only the two feet on the drive end bracket.  If I hog off too much material, theres a high likelihood of cracking.  It'd be great to get this bracket in cast iron or steel so I could thin out the feet with no issues.

 

 

[RedFred]

Dang those doors look good! Seems like it was pretty complex cutting too haha.

Can't wait to see what they look like when they're all done?

[WalledSonic]

Made a brace so I can bolt the pods to the door without bolts showing:

I still need to mat the door and add some damping

Clearance

Speakers in for test purposes

 

[WalledSonic]

The welder was a flake, so I took my parts back and bought a welder

The fan helps remove the fumes so I can see the weld

My very first weld

After a few practice beads

And today I decided to start welding my critical components.  Its not perfect!  But my windshield is thanking me for my efforts
Bottom brace:

Top brace

I am unbelievably happy with the welder purchase.  Its pretty easy to lay a (good-enough) bead and you can get projects like this done so much faster than relying on someone else.

 

[bsneon98]

damn man i love the crazy amount of custom fabrication in this build! That turnbuckle is different, cant wait to see what else you come up with!