|07-16-2002, 06:14 AM||#1|
Join Date: May 1997
Location: Pensacola, FL
How can I build custom kickpanels?
This is kick panels in a nutshell. It takes about 2 days to do this right, although it is possible to do overnight (a LONG night) in one vehicle.
Step 1: Cover base area with plastic & duct tape.
Step 2: Lay fiberglass over the entire area. Don't worry about getting the pieces cut to the exact size and shape, you will trim them later.
Step 3: Build the baffles for your speakers.
Step 4: After the fiberglass has cured, set the baffles (with the speakers properly mounted into the panels and use a backstrap to secure the baffle to the panels. Now, spend some time listening to the car and aim the baffles until you get the best image and stage in the car. Note: Take your time aiming the speakers -- once you fix the baffles, you won't be able to readjust the speakers. You may want to spend a few days listening to different positions to determine what sounds best.
Step 5: Remove the speakers from the baffle and fill from behind with self-expanding insulation foam. This will allow you to mold the baffle into the rest of the car.
Step 6: After the foam has hardened, sand it to the shape you want the panel to have.
Step 7: Lay fiberglass over the foam to form the top panel of the kick panel.
Step 8: After the fiberglass has hardened, sand the surface smooth. This may require the use of a little bondo to get things perfect.
Step 9: Remove the foam by grinding it out from the inside of the kickpanel.
Step 10: Cover the panels with carpet, vinyl, leather, fleckstone or other substance of your choice.
Step 11: Install the kick panels in the car.
Step 12: Install the speakers in the panels.
Step 13: Make speaker baffles from Plexiglas, and grilles.
Step 14: Enjoy.