Currently still working on the sound system, but will get some new pictures up soon of the build in progress! And, hopefully, some final pictures of the install! :-)

Quick Current Index:

1 - Sound Install Build
2 - Polo Concept

I decided for the design of my install, I wanted something a little bit different. So instead of using the standard parcel shelf, or even just changing the parcel shelf, ive incorporated the standard parcel shelf supports, to make one huge parcel shelf! Ive found this has made two big differences in helping the sound quality, the first being the shelf is now more rigid than ever, an the second being the speakers are placed further apart, creating a better �stereo image�. Below are a few pics of how I made the shelf:

This shows the parcel shelf supports attached together using block board for rigidity. The design on the shelf had already been cut out. I then stretched a piece of cloth over the entire thing, and soaked this with glass fibre resin to create a nice rounded smooth surface. For extra strength, this was then coated in a layer of glass fibre.

Holes for the 6*9�s where then cut out, and some filling began to get the shelf smooth.
Because of the different heights of the wood to the shelf supports where the speaker mounting holes where cut, extra pieces of MDF where attached underneath with glass fibre, an then filled to create a nice smooth mounting point. Because the original shelf supports where also used, this pic shows how well the new shelf fits.

(Experimentation with another glass fibre shelf can be seen in the background� it was my first one, an what can I say? We all learn form our mistakes ;-) ) This is the parcel shelf as it is at the moment, except with a coat of white gloss rather than primer. However it is not staying like this, and I am going to upholster it in the same suede used on the sub boxes, ill post more pics when its done!

The next main part of the build was the two subwoofer boxes. I wanted to bring the install completely up-to-date, and so MDF boxes were a definite no. I therefore decided to go for lower profile curved boxes, made from glass fibre. Mounting the subwoofers inversely enabled me to make the boxes longer, and shallower, so keeping the required air volume, but leaving enough space (just) to fit the amps centrally in the boot.

I wanted to first get the heights of the top and bottom pieces correct before putting any of the sides in. To do this I used some rough offcuts of scant. Knowing the top and bottom pieces where the correct height, I could then concentrate on fixing any sides in the correct places, and attaching the main sub mount. The pic shows one sub box before fixing, with rough scant, and one of the sub box frames complete.

This shows one of the sub boxes after glass fibre has been applied. In order to create the round, curved shape, I stretched cloth over the sub box frame, and stapled it around the edges. To avoid flexing (which can cause sound degradation) due to the pressure created inside the box by the sub, the glass fibre was layered thickly. I decided to go for 10� subs because I prefer tight punchy bass, and for this reason the sub boxes were also not ported.

Beginning of sanding. Even though the boxes will be upholstered, I want them to look and feel smooth for that quality touch!

Some of you may have noticed a strange hole in the top of the box. Because of the new positions of the 6*9s, they were exactly on top of the sub boxes. So I made a special cut out to accommodate these, and created and sealed this hole with more glass fibre, again using the previous method or using stretched cloth to get the shape I wanted. The back has also been added and the whole box has been sealed with a thick layer of mastic to ensure the box will be completely air tight.

In order to prevent any colour showing through the suede, I gave the boxes a few coats of primer and then black paint. Unfortunately the suede was not as stretchy as I first thought�. The first box taking nearly 4 hours to stretch the suede into being completely smooth! On the right you can also see the speaker terminals added, and again these were fully sealed within the box.

Also built at the same time as the sub boxes was the false floor and amp rack. These were relatively simple in their manufacture, but the design is the real advantage. The false floor was designed to house the spare wheel (even if it is a space saver), and an extra battery + electrics.

This shows the first trial fitting of the false floor. It is basically two layers, and the top has panels cut out for access. This is made of block board. I decided to use a sealed second battery, so there was no need for a completely sealed battery box.

Top view of the floor, you can see where routing has been done. The central two are for the amp rack to slide into, and the outside two are for locating the position of the sub boxes.

Quick pic of the amp rack before painting. May not be much, but it will hold the amps in the correct place and cannot be seen. I gave it a few coats of black so as to disguise it completely.

To neaten up the false floor, boot carpet was used to upholster the base, and suede was used for the top to match the sub boxes.