By Gary Biggs
This is a really great technique for creating small projects such as tweeter pods. With it, you can build great-looking pods in about an hour! Once you've learned this method, try it for many other projects.
The first step is to remove the factory mirror panel. Randomly drill 11/42" holes in the panel. Saturate the entire panel with the CA glue and spray the accelerator over the area.
Remove the body filler from the can and mix in the appropriate amount of hardener according to the manufacturer's recommendations. Once the body filler cures, remove the excess by sanding or filing. To rid the viewable side of any imperfections, evenly apply a thin layer of body filler over the entire face of the panel.
Lightly scuff the panel with a Scotch-Brite pad. This removes any peaks in the texture coat, leaving you with a nice, smooth texture similar to factory plastic.
Once the panel has been removed, wipe it clean with lacquer thinner and scuff with 80-grit sandpaper. Be sure to do this and the following steps in a well-ventilated area. Stretch a piece of thin speaker grille cloth over the panel, gluing it to the top of the tweeter cup and around all of the edges of the mirror panel.
Now it's time for the Landau Black paint. Hold the can about 12" away from the panel and apply several coats for a uniform look.
Using 120-grit sandpaper, sand the panel smooth.
Once you've finished mixing, quickly fill a cake-decorating bag with the body filler.
Remove the extra material from the edges. Then, using the 80-grit sandpaper, sand the panel smooth.
For the finishing touches, we'll use Texture Coat and Landau Black paint from SEM. Starting with the Texture Coat, hold the can about 12" away from the panel and apply several even coats.
Using a piece of 80-grit sandpaper, scuff the tweeter-mounting cup. Attach the plastic tweeter cup to the plastic mirror panel with quick-set CA glue, such as SP 108 from Select Products, and activator.
Flip the mirror panel over and insert the application end of the decorating bag into each of the pre-drilled holes and gently squeeze until the cavity is filled.
Install the tweeter and you're done.
Last edited by mikel7829; 06-10-2009 at 08:07 PM.
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