starting on the gustom door panels - Ford Powerstroke Diesel Forum
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post #1 of 32 Old 07-23-2013, 07:17 PM Thread Starter
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starting on the custom door panels

ok guys here it is, the write up of how I built my door panels.
I am installing 2 set of Hertz 3way components in the front doors and a set of 2way components in the rear doors.
so I have 2 6.5"mid bas drivers, 2 3" mid range, and 2 1" soft dome tweeters in each front door. my issue was trying to figure out placement of everything. I had originally wanted to take 1 3" and a tweeter and mold into the "A" pillars to bring up the sound stage, but once I had built the plate for them and test fitted. I didn't like how it was fitting so I decided on the mirror pillar on the door
the first step on the pillar was to build the mount for the 3" and tweeter. Using 1/2" mdf, a router, a couple hole saws this is what I came up with
Attachment 144105
with the shape decided on I had to put a ring around it for the grill. I used a low heat formable plastic cut at 7/8". 1/2" for the mount, 1/8" for the speaker ring thickness, and 1/4 " for the grill.
I stapled it around the mounting ring and this is what I had.
Attachment 144113
once that was done, I had to attach a bottom plate to the mirror pillar
starting on the gustom door panels-img_20130723_105947_104.jpg
in order to fiberglass to plastic and have it hold really well you will need to scuff up the plastic. all I did was take a die grinder and grind the mirror pillar.
starting on the gustom door panels-img_20130723_162302_653.jpg
once that is complete I added the mount ring to the mirror pillar.
Attachment 144137
now comes the fun part. wrapping it in fleece, yes sweat shirt material.
walmart or a fabric shop for that, just make sure it's really stretchy.
starting on the gustom door panels-img_20130723_114207_001.jpg
with that completed time to mix up some fiberglass resin. just brush it on, make sure you get it to soak all the way thru. I like to add fiberglass chop matt after I soak the fleece. while it's still wet lay 1 or 2 layers of the chop matt, wetting each layer before adding the next. give it time to fully dry and this is what you get.
starting on the gustom door panels-img_20130723_132913_702.jpg
once hardened, take your die grinder and clean up all of the edges and scuff it up all over to give body filler better adhesion'
now it's time for the body working. I like to use Rage Gold for the lite work, if needs more building up then I use DynaGlass.
I laid on a medium coat of the Rage Gold. I little tip, don't wait for it to fully harden before you start your sanding, I use 36 grit when it is still soft but not too soft. if it makes small rolls give it a minute or too. you want large pieces of dust. 36grit will take it down very quickly, Oh USE GLOVES!!! otherwise you will not have finger prints when you get done.
I will add more once I get the actual doors further along

Last edited by bulldogsf350; 07-23-2013 at 07:26 PM.
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post #2 of 32 Old 07-23-2013, 07:22 PM Thread Starter
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ok for some reason some picks didn't post so here they are.
starting on the gustom door panels-img_20130722_175804_842.jpg

starting on the gustom door panels-img_20130722_175832_134.jpg

starting on the gustom door panels-img_20130722_183626_487.jpg

starting on the gustom door panels-img_20130723_112551_440.jpg
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post #3 of 32 Old 07-24-2013, 08:59 AM
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Can you cut me out a couple of them? I would pay you. Looks good.

I used to think high mileage was a bad thing, but its a badge of honor on my F250 Powerstroke.
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post #4 of 32 Old 07-24-2013, 05:41 PM Thread Starter
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Thanks, I would need to know what speakers you were trying to install so I know what size hole to cut, also what shape are you looking for? and where are you trying to install them.
Here are the final pictures of the tweeter pods
starting on the gustom door panels-img_20130724_125431_318.jpg

starting on the gustom door panels-img_20130724_131525_192.jpg

starting on the gustom door panels-img_20130724_131825_737.jpg
T Howard likes this.
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post #5 of 32 Old 08-04-2013, 05:30 AM
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Personally I'm not a stereo guy, basic stuff is normally ok with me buy your fab skills are great... same methods could be applied to mods on the dash for moulded on/in multi-gauge pods, etc. Nice work... very clean install.

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post #6 of 32 Old 08-05-2013, 02:56 PM
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Very nice! You could make some $$$ selling those! Just pump em out with tweeters already installed

--7.3
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post #7 of 32 Old 08-08-2013, 05:41 AM
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Thats bad *** dude! Your truck is coming along NICE!
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post #8 of 32 Old 09-07-2013, 05:10 AM
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I love it man!! that install looks really sweet, slick and clean......

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post #9 of 32 Old 09-09-2013, 05:34 AM
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Quote:
Originally Posted by bulldogsf350 View Post
Thanks, I would need to know what speakers you were trying to install so I know what size hole to cut, also what shape are you looking for? and where are you trying to install them.
Here are the final pictures of the tweeter pods
Attachment 144577

Attachment 144585

Attachment 144593
If you could make me a set of speaker mounts just like what you have, a 3" and a 1" hole I am going attempt to make one just like yours. I may in fact use Hertz speakers also. I am only talking about the peice of wood with two holes.

I would happily pay for your time, wood and shipping...

Everything you have done, looks like is was done well...

I used to think high mileage was a bad thing, but its a badge of honor on my F250 Powerstroke.
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post #10 of 32 Old 01-26-2014, 10:01 AM
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Great looking pods! Can we get some updates? I'm pulling inspiration from your posts!
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