Well ive been planing to do this for a while waiting for some decent weather and free time... i was suspended from work for the stupidest of things yesterday so i thought i might as well put the paid time to good use LOL! CHEERS WORK!! LOL!

Well this is the first time i will be doing a door card ive done a few kickwell pods and sub boxes so dont slaughter me if it aint 100% text book!

i picked up some mashed up door cards from a forum member for a tenner RESULT! as you can see they are grey but since they are gona get retrimmed professionaly it doesnt really matter

Picked up a 3x2 foot 6mm sheet of MDF this morning and a hot glue gun! Homebase have a 10% off today RESULT number 2 LOL

I forgot to buy a compas so i improvised!

Actualy worked better than i imagined!

I used a dremmel to cut away the door card it was quite fiddly and took a little while to find a nice angle

Measuring up the struts and fitting them in is not as easy at it looks... fiddly but easier if you have a dremmel handy

Yeh looking good if i say so myself! just the angle i want and not poking too far our either. i figured a max of 4 or 5 inches out woul not intefere with my leg

SOLID! i figured i should angle them in a certain way that would give strength to the whole thing, im going to be fiberglassing the struts to the wood for added strength as im not sure hot glue is suffient. better safe than sorry right?

Well i got the smaller 5inch component in there its not really angled enough for my liking so its getting ripped out and done again but its looking good here's where i left off today

plenty space to clear the metal skin inside it really feels so delicate at the moment. im looking forward to getting and old tshirt stapled to it and resin it up! should be mega strong then

Any comments good or bad and any helpfull tips if you guys have any would be much apreciated!

Ian

DJUPLIFT:

Any comments good or bad and any helpfull tips if you guys have any would be much apreciated!

Your midbass will sound awful,a flimsy doorcard isn't anywhere near sturdy enough to mount any midbass driver,let alone a heavy 8 in one like that.
You're driving round in one of the best mobile speaker cabinets ever made (one reason I bought a mk.4) and you're effectively mounting a bass speaker in a cardboard box without a back to it.I've spent several hours today finishing off the soundproofing in my drivers door and I can already hear that door sounding better than the passengers side that doesn't have any.

Chris.

Oh and stop messing about with old t-shirts,they don't soak up anywhere near enough resin to be of much use,get some proper fleece mould cloth from the guys below.

http://www.selectproducts.org.uk/

Chris.

Oh and one other thing.....there's no need to angle the midbass as there's no imaging cues below about 500Hz,you won't hear any difference if they're like that or playing to your ankles as long as you're on axis to the mids and tweeters.

Chris.

I knew youd be on quick chris lol... i know about the midbass not having to be on axis but it just looks better that way. also i have a little plan up my sleve as i know the mk4 door cards reign supreme... wait and see ive already got a solution.

cheers for the link for the fleece! much apreciated

The saga continues tomorrow weather permitting i test fitted the door card today and must say it looks good. will get some more pics up tomorrow!

you should check out realmofexcursion, theres some good guides and a lot of help on this kinda stuff.

hehe cheers yeah i know alot of the guys on there already... they are well off the wall tho. with yanks its gota be bigger or its not better lol!

I'll keep my eye on this DJuplift, I still can't afford my upgrade yet so I can take my time (months and months!!), and have been wondering about door builds. I was thinking of cutting away the whole corner of the door card and fixing the pod directly to the metal skin... but looking at how its all supposed to come apart if the window motor goes or whatever, looks very difficult... and trimming it up afterwards would be a headache...so, I'll see how you do it !

Good luck

Cool mate ive got it on hold at the moment as the weather is not too great at the moment. but ill show ya exactly how im going to build the back side of the door card so that it bolts to the metal door skin to make it solid as a rock.

Hows it all going/gone?

~J

Just waiting for the good weather to come back. Hopefully next bank holiday will be nice and ill get these finished off. Well at least the fiberglassing. Might also have time for some testing of the subs and mids in place and also finding the sweet spot locations for those high mids and tweet's.

Little update... ordered some parts. body filler, fleece, brushes, acetone, a good staple gun and now all i need to get is resin and hardner.

fingers crossed the weather is good this weekend and i get some time to myself!

cant wait to see this finished

i am thinking of upgrading my speakers etc

hafizur

Heres a lil teaser of how its comming along... sunny weather + day off = PROGRESS!

I bought the material from these guys http://as-essentials.co.uk/ (thanks to blackmagic20vt for the link) not sure if the prices are good but i didnt care lol. i picked up body filler, spray adhesive, the fleece and some other bits and bob's.

Ive actualy stretched it out a little bit more in some areas as it started to crease back in as. i can conclude its NOT an easy job as it looks, specialy if you have a crap stapler like i did... i couldnt recommend any make of stapler but if you can get your hands on an powered one im sure it would be MUCH easier.

im gona try and make a few adjustments tomorrow if the weathers still good ill resin it up and start to fiberglass the insides for strenght. should be fun!

More good weather equals more progress... doors now resined up, will need some dremel work and some more resin on the underside with some fiberglass matting to really get this solid. heres some pics of what i did today

well done for having ago pal, looks good to me and will keep my eye on this to see how you go on 

Cheers Lee...

Crap weather today means no progress... anyone wanna send me some sunshine?

 no sunshine sorry djuplift, but was going to ask your advice on fitting some 6*9 in the rear parcel self as you seem handy at this type of work and i just stick to mechanical, am going to upgrade my stock radio for a bluetooth one and run a amp to the 6*9 but not sure how to get them on the shelf

The stock rear parcel shelf is pants for holding any sort of weight. Do yourself a favour in the long term and get a stealth shelf if you're gonna go the 6x9 route.

i would not drill through the parcel shelf, its like 50 quid alone. i cut through some 10mm wood and fabricated that.

drfeelgood:

The stock rear parcel shelf is pants for holding any sort of weight. Do yourself a favour in the long term and get a stealth shelf if you're gonna go the 6x9 route.

Couldnt agree more with the above. but i have installed some Vibe QB69 that weigh a ton on a modified mk4 shelf with good results. If you do want to go the cheap way as i did for my mate use the speaker grills to mark out with chalk on the shelf where you wanna position them then use some strong contact adhesive like green gripfill or pinkgrip kinda stuff to glue MDF to the bottom of the shelf, then mounth the speakers thru the parcel shelf into the MDF, gives good results.

But the best results are making a new thick shelf from two sheets of MDF stuck together and trimming that up.

 thanks very much for advice am more then capeable of doing this so will do it next dry day.sorry for hijacking your thread djuplft

no problem mate!

i love these kind of posts where people show what they're up to, the only thing i hate, im not saying this in any disrespecting way is waiting to see the end product, im sort of a new member so when i first joined there were all these posts i could pop into and follow them to the end

but yeah, rant out the way, looking good, looks like its gonna be crazy in the car once its all done

I gonna agree with Chris, the door cards are gonna vibrate like mad...unless you have some cunning plan to add some reinforcment, that you have yet to reveal!

TDIRich:

I gonna agree with Chris, the door cards are gonna vibrate like mad...unless you have some cunning plan to add some reinforcment, that you have yet to reveal!

Several hundredweight of concrete maybe like I was going to line my sub box with.

Chris.

There is a very cunning plan on the way. wont be revealed... unless u pay! LOL!

bit of an update too... managed to grind down and neaten up the edges...

 Whats happening ian! that is looking good, cant wait to see them finished, would love to do this to mine! why am i so crap at do this type of DIY!?  oh well cant wait to see and hear them!

Cheers mate... they are shapeing up nicely, few touches with some body filler and they should be ready for stage 2!

Looks good mate.. thumbs up for giving a go yourself.. are they spare doorcards?

yeave ive got the 4motion leather ones in mine at the moment.

not much of an update but i thought id try the sub and 5inch component to see if i needed to shave down the inner diameter to accomodate them and thought i might as well take some pics to show how its gona look.

enjoy!

i sure hope you can close your door ian! lol they looks awesome!