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

[WalledSonic]

Got the face boards going

(2) layers of 1" birch. I plan on bracing the wall internally, details forthcoming this week

Heres the boards mocked up

[WalledSonic]

Holes cut

Much bracing to come

Showing the layout

Dat veneer

[Karkov]

I had that crimper before i got the one I have now. I liked that one ^^^^ a ton better. =(

[WalledSonic]

Been working on the wall/face bracing this week. The window bracing doesnt line up perfect with the sub holes, but I can fit this 2x3 in there. I like it offset toward the port a bit since the port walls are only 1 layer thick.

Laying out the cutouts for the top and bottom bracing for the wall

Routed on one side to prevent chuffing.

Here's a pic of the bottom brace in

And the top

[WalledSonic]

All the pieces are predrilled or kreg'd, ready to go

[WalledSonic]

Hardware for the speaker connections came in. A 3' long brass all-thread rod and 50 brass nuts. This gives me ( 8 ) 4" long pieces to mount on the back rear wall of the enclosure.

Since Im limited on alternator power, minimizing voltage drop is a key concern.

[WalledSonic]

Ran across a fusing thread yesterday started by @redfred and realized my long cable run should have a fuse on both ends between the front batt & rear bank.  I only have one in the rear, currently.  So I pulled the underhood setup and started on a new bus bar and fuse block.

Heres the stock fuse block for the ECU, starter/alt, etc that normally connects direct to the battery terminal: my finger is on the starter/alt cable.

 

Old bus bar (already been used for two different setups) VERSUS the new bus:

[WalledSonic]

I'll preface with 'do not try this at home':

 

Some careful cuts later:

 

Im using my router really carefully here:

 

Getting fitted

[WalledSonic]

The copper distribution block I made today connects:

1) Fused alt/starter

2) Fused ECU

3) Fused front battery

4) Fused rear long cable run

 

Crimping feels so satisfying now

 

Heres the block after some fancy cuts.  I forgot to snap a pic of the bar by itself, but you can see the shape of the final product

 

 

[WalledSonic]

Left this tab on just cause

 

 

Final setup:

I still need to unstack the battery connection lugs in the pic above, but thats all I could finish today.  Thanks for looking!