Just embarking on the custom stereo intallation. This first step is very boring, but it will progress over the next few weeks to something more interesting.

A sub and two 6x9s will be housed in this parcel tray. Amps will be located under the bonnet, and the 6in speakers and tweeters in footwells in aftermarket speaker kick panels.

Kickpanels arrived the other day. Just sizing them up for now - will need a little trimming and fine tuning to get them spot on.

Not a bad bit of gear - the fibreglass is nice and thick (not the plastic ones available some places). 5 1/4in speakers and tweeters will be finding their way into these panels soon.

Fired up the router to make a sub mounting ring tonight...here it is half way through (router ensures ring is perfectly round.

Here is the ring complete - inside was cut with jigsaw since this edge won't be seen.

Slowly but surely the rear sub enclosure (sort of an enclosure since it is a free air sub) and 6x9 mounts take shape.

Started the sub box - spent lots of time measuring and working out how to get it to fit under the rollcage. Anyway, marked up the sides of the box on 16mm MDF. The sub will be angled towards the back seat but not right up against it.

Here is the side panel rough cut with a jigsaw (remember to use dust mask because the $hit in MDF is not good for your lungs). A little bit of material was left alongside the marked lines.....

.....so a flush cutting bit on the router table could be used (with a straight edge [factory cut edge] as a guide). This way a perfectly straight cut can be achieved so the box is perfectly sealed (although putty/silicone will be used as well).

Just make sure you feed the material in the right direction so it doesn't kick back. Perfect edge every time (as long as your guide is straight!).

Here you can see the box half assembled - edges glued and screwed. The angled portion at the back lower edge is so the box can fit hard against the firewall without butting against the rolled (curved) lower corner on firewall.

The box will have a top (which I ran out of time to do), but the sub ring will be perched atop so the fibreglass will have a more interesting shape to follow than a flat board. This is the first time I've done this so I'm learning as I go.

Here it is temporarily in place - work to continue this week. The extra material on the base is so it can be bolted down to the body (to avoid easy theft).

Here you can see the completed sub box (middle section) as well as outer skeleton which will provide the framework to house the 6x9's.

The joints of the box were siliconed inside to provide an effective seal (should be pretty much air-tight for effective sub performance).

The 6x9 mounting rings were hot glued in place (had to make sure the angle was symmetrical!).

You can now see how it is all coming to shape.

Pioneer sub in place with Kicker cover, and two pioneer 6x9s. None screwed in place - just checking fit etc.

Started to staple the stretchy material into place as this gives the shape the fibreglass will form.

Ran out of time to finish the staple job - may have to put a few more MDF skeleton pieces in place to give it the desired shape.

Did a bit more work on the sub/speaker enclosure tonight. To get the desired shape I had to put some more MDF support pieces to enable the material to be stapled in place.

The enclosure is upside down if you didn't figure out already....the hot glue gun holds the support pieces in place - the fibreglass will provide the strength required.

Couple of other little pieces to complete the skeleton framework. Again sorry for the multitude of pics...thought its better to have too many than not enough.

Here the material is stretched into place ensuring there are as few folds or wrinkles as possible.

This gives you an idea of the shape of the enclosure - resin was applied to give the material some stiffness so the fibreglass mat can be applied.

Last pic for now. Next up is Fibreglassing-101 (my introductory course). Best way to learn is to give it a crack I guess!

Slid the sub enclosure into place tonight to check fit (fortunately everything went in easily!).

Access cutouts in the front face of the enclosure are so I can A) bolt it all down, B) access 6x9 wiring, and C) access coil which will be mounted on the firewall. Another coat of resin tonight to stiffen the material a little more.

Laid down the first couple of layers of glass mat - messy job! First time so I am sure that its not perfect, I'll get better with practice though!

Layed down a few more layers of glass and resin. Allowed it to cure then sanded it back a little to get rid of the nibs etc.

First layer of filler today then ran out of time - this is in preparation for paint which will be in the near future. (at least high build primer etc and will spray the body colour when I paint the rest of the car).

Filler work on the sub enclosure continued today....

...and continued some more! Looking a little better with each application of filler/sanding etc.

High build primer was laid down which improved things further. Speakers just popped in place to check fit again.

Still a bit of glaze putty required to fill in some minor holes scratches etc before base coat goes on down the track.

Started the amp rack today but didn't get too far (ran out of time)....both amps to be mounted under bonnet via 16mm SHS (square hollow section) steel frame that will be bolted (via mounting nuts)....lots more work to come on this one.

Finally finished welding the amp rack tonight. Bit of fiddling around to get the angles right (three hands would have been helpful!)...haven't cleaned any of the welds up yet - just got it together for now.

Had to ensure it cleared the fuel tank and wiper motor.

Originally I was going to weld another support brace for the upper tier, however after fully welding all the joints there was no movement whatsoever even with a fair bit of pressure. So it will stay as is.

I won't be using the stock wiring cover - I will be making another custom fibreglass cover around the side of the amps to hide the wiring etc. That will come later.

New Dynaudio 240GT splits have replaced the previous ones...very much an upgrade! Can't wait to hear them in the car!