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Discussion Starter #1
After some recent interest in what went into creating the door builds I thought I should create a step by step guide to installing 3-way components.

http://i164.photobucket.com/albums/u30/zegalini/2008PPC/_DS36192.jpg
http://i164.photobucket.com/albums/u30/zegalini/2008PPC/_DS36195.jpg
http://i164.photobucket.com/albums/u30/zegalini/2008PPC/_DS36198.jpg

The setup on display is a 165mm midbass, 100mm midrange, and 40mm tweeter.

Create some mdf rings to fit the midbass and midrange speakers. Now remove the door card and cut a bloody big hole where the original speaker used to be and another hole just above where the midrange will go.

Now fix the mdf rings at no less than 2 points - strength is not of the utmost importance just yet, but that doesn't mean bodging it.

http://i164.photobucket.com/albums/u30/zegalini/Door_builds/CIMG2187.jpg
http://i164.photobucket.com/albums/u30/zegalini/Door_builds/CIMG2187.jpg

Now find some cotton fabric and stretch it around the door card, stapling and trimming as required. I stapled along the back edge of the door card in order to begin stretching the fabric around.

Now cover the fabric in fibreglass resin, applying layer after layer around the speaker holes (not so much in the holes - just enough to bond it to the mdf) and anywhere the fabric touches the door card.

Allow this to dry and apply more fibreglass resin to the back of the door card creating a bond around the holes and mdf rings. I had to fibreglass around the tweeter hole as I required a smaller hole (insert comedy ending here).

http://i164.photobucket.com/albums/u30/zegalini/Door_builds/CIMG2195.jpg
http://i164.photobucket.com/albums/u30/zegalini/Door_builds/CIMG2192.jpg

Once the resin is completely dry (24hrs) start sanding and filling. This is the most time consuming part of the job as you can spend as much or as little time as you want perfecting and shaping the new door card.

http://i164.photobucket.com/albums/u30/zegalini/Door_builds/DoorBuilds1.jpg
http://i164.photobucket.com/albums/u30/zegalini/Door_builds/DoorBuilds.jpg

As far as covering the door cards, I found it best to approach a professional as it requires a certain amount of experience and skill that I am sorely lacking. I opted for back vinyl in order to match the original material.

I hope this helps anyone who is thinking of doing the same or is just interested car audio.
 

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AO Silver Member, 155 Lounge Winner 09
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very nice work. is the imaging/soundstage good with those angles/position?

just remember, most people here either don't have the skills, aren't prepared to cut the trims, or aren't willing to pay pro installer what it costs to do such work. ;)

but again, top job.

:)
 

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Discussion Starter #4
is the imaging/soundstage good with those angles/position?
It's still not as good as having the tweeters and midrange mounted under the front windscreen but if the time correction is adjusted you get some very good imaging. For me it was the simplest option as Rainbow recommend grouping the components together but, I don't think it would sound too bad if the midbass was in the door and the midrange and tweeter was in the dash. The damn car is so noisey on the road that I sometimes wonder if putting quality sound into the GTV was a wise .

Would you be willing to make a few and sell them off?

I would be interested in that :D
I'm not sure if that would make financial sense, the door cards cost £200 at least, the vinyl is £125 on its own, you could easily cost it at £500 per set of door cards. When it comes to selling the car, I might remove the door cards if I cannot find a decent 3-way component set to replace the current ones. I'd even be willing to sell them for £50 and 2 replacement door cards. BUt that would be a few years from now.
 

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AO Silver Member, 155 Lounge Winner 09
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7,713 Posts
It's still not as good as having the tweeters and midrange mounted under the front windscreen but if the time correction is adjusted you get some very good imaging.
sounds like a good compromise.

when i see some cars with 4" midranges + tweeters built in custom pods on A-pillars or dashtop, i always think..."how can you see out the windscreen with those build-outs in the way?!".

dashtop mids+tweeters can certainly sound great, with high/wide/deep soundstage. but i prefer a more stealth look, and not dog's-balls speakers shouting out "i have expensive ICE in my car...come steal me". :p i think you've done a great design.

when i had a 156, i put mids+tweeters in the kickpanels, custom pods. angled up, they imaged really well, but stageheight suffered. so i ended up adding in ambient tweeters in the A-pillars which helped a lot. kind of a 3.5-way setup. but it was complex to design/tune/install. having been-there done-that, i've now reverted to top-shelf 2-way instead (Dyn Esotar + Morel Supremo Piccolo)! much easier, and still sounds as good, possibly better. anyway, 3-way can be great/better if installed nicely, but at the expense of simplicity.

:)
 
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