Inner Quarter Panel Speakers and Subwoofers

[dsmith01]

Since I haven't decided to sell the Bronco yet and Jocelyn was studying for a certification test all weekend I decided to build some speaker boxes that fit into the quarter panels. I wanted to build some panels that could fit a single 10" subwoofer and a 6.5" component speaker and tweeter. I also wanted to fit the crossover and amplifiers behind the panel and out of sight.

After a ton of research I ended up with a Rockford Fosgate PBR300x4 amplifier. This is the smallest amplifier I've ever seen and will put out 75 watts RMS to each component speaker. I choose Cadence 6.5" components for the speakers.

Here is what I have finished so far. The panels/boxes still need some bondo work on the front to make the speaker rings taper down and finished will carpet.







One question I have is how thick is too thick for bondo on wood? To get the right amount of depth for the shallow mount subwoofer I need to stack 2x 3/4" MDF rings on top of each other. I was planning on tapering down to the panel with bondo but that will leave me with up to 1 1/4 of filler around the ring. Is this too much? Here is a picture of the panel with the 2 stacked rings.

[ZOSO]

I would glass that in. I wouldn't run any bondo more than a max of 1/4". There will be a lot of vibrations there so glass is your best bet.

[dsmith01]

I was afraid of that. I hate fiberglass!

[B.O.B.]

That is exactly what I am looking for. I agree that glass would definitely be better.

[Eck]

Do you by chance have all of the measurements for this? I'm looking to do this same type of thing shortly. Also- I had thought of putting the amp in the same location-- do you think it will be highly susceptible to overheating in such an enclosed area?

[dsmith01]

Do you by chance have all of the measurements for this? I'm looking to do this same type of thing shortly. Also- I had thought of putting the amp in the same location-- do you think it will be highly susceptible to overheating in such an enclosed area?

Wouldn't be hard to get the measurements before I glass the front. I'll see what I can come up with tomorrow when I get home from work. I didn't make the panel extend all the way to the back of the door post because of my roll cage and seatbelt retractors. Felt like it would be too much reworking to make sense.

The amps are open to about 2-3" towards the quarter and about 2 square inches of cavity above them inside the quarter. I think this is enough ventilation space.

[Jesus_man]

Great idea! I love it! I need something a little better and Ipod friendly in mine. Was thinking of trying to find some smaller Marine speakers like on wake board boats, but this is a great idea too.

[dsmith01]

Do you by chance have all of the measurements for this? I'm looking to do this same type of thing shortly. Also- I had thought of putting the amp in the same location-- do you think it will be highly susceptible to overheating in such an enclosed area?

I got out to the garage and did some more work on these tonight and took measurements of the front pieces. I'm going to load them into a sketchup model to make things easier. Should have it finished up tomorrow or Wednesday.

I decided to use some flower styrofoam to build up the speak holes. I used liquid nails to hold it in place and then used a course file to grind the foam down to the general dimensions I want. I'm going to cover the foam with a thin layer of bondo that will seal the styrofoam.



I got bondo on one panel tonight and will finish up the other tomorrow. Will share pictures of the sanded down panels.

[dsmith01]

Here's the sketchup of the panels.

http://homeofdrock.com/?wpdmact=process&did=NS5ob3RsaW5r

Should answer any measurement questions but let me know.