DIY Network

Acrylic Subwoofer Enclosure: Prep Work From "Tricked Out" episode DTRK-113

	The project car: a 2001 Toyota Celica with custom paint, Euro-lights, and a carbon-fiber hood.
	Today's project: installing a clear-acrylic subwoofer enclosure for great looks and some serious "boom."

In this episode of Tricked Out, host Andrew Totolos installs an acrylic subwoofer-enclosure on a Toyota Celica. In this first segment, he introduces the project car -- a 2001 Celica with a high-tech exterior and some tasty interior and engine modifications, but with a less-than-spectacular speaker-box. He begins the project by removing the old speaker box from the car.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

10" subwoofers
3/4"-thick transparent acrylic (precut to fit your design)
Speaker wires
Terminal plates
Wire connectors
Straight-edge
Measuring tape
Pencil
Jig saw
Several fine-tooth jig-saw blades
Drill and bits
Hole saw
Clamps
Masking tape
Methylene-chloride acrylic glue
Syringe applicator

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

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DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale. There's some cutting and drilling involved, and working with the acrylic requires some patience, but mechanically and electrically it's not that complex.

In this project, we replace the old, existing subwoofer and enclosure (figure A) with a new, high-tech system with see-through acrylic enclosure (figure B).

Figure A

Figure B

When installing a subwoofer and enclosure, consider the type of music you'll be listening to. For standard fare and most rock-music genres, and allowing for loud volumes, a sealed box (figure C) may be preferable. A sealed box contains the sound and forces most of the sound frequencies to be transmitted via the speaker cones, resulting in a "punchier" sound.

For bass-heavy styles like hip-hop, dub, dance or trance, you may want to consider a vented box (figure D). The vented box allows for fuller, deeper-sounding bass by enabling the bass-frequency sound waves more time to expand before they reach your ears.

Figure C

Figure D

Figure E

For automotive applications, you want to make certain that your speaker box is strong and durable, but also lightweight. Most are made from MDF (medium-density fiberboard). As a building material, it's inexpensive, strong and easy to work with. The drawback is its drab appearance. Some boxes are "dressed up" using fabric, carpet, or undercoating. For our project, we opted to use 3/4" clear acrylic for our box rather than MDF. It requires some special handling, but the look you get is impressive, and shows off your audio components. The speakers we chose were 10" subwoofer cones. The 200-watt amplifier on the existing subwoofer system (figure E) was fine for the new application, so we simply transferred it to the new system.

	Figure F
	Figure G

Removing the Old Box

• Before you begin the project, disconnect the negative cable from the car's battery to prevent damage to your electrical system.

• Disconnect the speaker wires and power wires first (figure F).

• Then flip the box over and remove the input wires from the head unit (figure G).

• With all of the amp wiring disconnected, you can pull the box out.

• Disconnect the amp and set it aside because you'll use it later in the project. If it's still in good working condition, the amp can be used in the new speaker box.
  

  	Under the hood: Engine mods include throttle cam and cold-air intake that pushes air through to a stainless-steel exhaust.
  	The interior includes additional carbon-fiber, custom gauges and racing seats.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

RESOURCES :

Crutchfield Car Audio
Crutchfield is not only a catalog retailer specializing in a wide array of popular audio equipment, they excel at providing information and resources for audio-system installation by car owners. Their Crutchfield Guide: Car Stereo Installation offers valuable information on installation of components in most vehicles. Their free catalog offers advice on selecting the best type of system for your tastes and the most suitable equipment for your vehicle.
Crutchfield Corporation
Website: www.crutchfield.com

Auto Audio
Model: 0071346899
Author: Andrew Yoder
Publisher: Tab Books
Order this title from Amazon.com.

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Special Resources for Tricked Out, episode 113

Stillwater Designs/Kicker
Website: www.kicker.com

Racing Innovations, Inc.
Website: www.racinginnovations.com

The12Volt.com
The 12Volt.com is a specialized website devoted to providing technical information for mobile electronics installers as well as professional tips and tricks. Included are a mobile electronics glossary, charts, diagrams, specs, calculators and general information on car-audio, security systems, cruise control and other automotive electronics systems.
Website: www.the12volt.com