Full Version: Rebuiding Inside-out
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Then I did the same on the right side.
Time for a new white board list. Engine stuff still has to wait for getting my case back.
QUOTE(bkrantz @ Jul 21 2021, 05:42 PM) 
I trimmed the liner with a jig saw.
Did the same in a number of places for a "better" fit.
QUOTE(bkrantz @ Jul 21 2021, 05:52 PM)
That should be enough to keep the liner from shifting inward.
Great idea!
New hose and grommet stock!
Grommets are for the same hole size (20-22 mm) but with inner diameters for the plastic tubing or the braided hose.
Plumbing done in fender well.
And along the rocker.
Into the engine compartment.
And by the fuel tank.
Then I got out the rocker covers. They are a little lumpy, but I had them powder-coated so no filler allowed.
I used stainless screws so I can easily open things up for cleaning.
Left side on, and now I can finish the fender liners.
I started on the left rear fender liner. I modified another clip for the leading edge
Leading edge clip in place.
On the trailing edge, the clip just reaches the hole.
Test fitting the liner. It sits snugly against the outer edge, but leaves a gap along the inner wall, just in the line of fire of debris coming off the tire.
Time to use some 1/8" rubber sheet, pop-riveted to the liner.
Of course, today my rivet tool choked on one of the studs. I had to take it apart, and then it took me three attempts to get it back together and working properly.
First fitting attempt: a bit wobbly.
Second attempt: some slits, and the flaps lay tight against the inner fender.
Of course, fussing with the rear side made me think about the exposure on the leading side. Stuff going this way creates the classic dirt pile inside the rocker covers.
Maybe something like this? I need bigger rubber sheets. And to think some more.
For now, it looks like this.
The last thing I did today was mount the right side rocker cover.
Next interior bit: speakers and pods.
I decided to use the standard design, since they take less physical and visual space. And since audio is a secondary goal for me.
I decided to use the standard design, since they take less physical and visual space. And since audio is a secondary goal for me.
Here's how the left side fits, with limited space inside the box--as everyone knows.
I got these Infinity plate speakers, which should fit, as bbrock demonstrated.
The right side box sits too high for the screw holes to line up, by about 2 mm.
I used a new utility blade to shave about 1.5 mm off the base edge.
That was enough for things to line up.
Now to develop some speaker mounting adapters.
I made these from 1/4" MDF. Once I get some hardware I can see if everything fits.
Here is my first version: the mounting board sits between the grill and the speaker.
That leaves almost 1/2" between the grill and the face of the speaker.
It does sorta fit, by bending the pod a bit.
Here's the problem: the magnet of the mid-range speaker projects beyond the mounting plane of the back side of the pod.
Here is version 2. Like Brent, I moved the mounting board to sit on the back side of the speaker plate.
Modified boards, repainted.
One more mod: for the speaker to sit closer to the grill, it has to sit between the pod mounting studs. But the speaker plate is about 4 mm too wide.
So, a quick trim of the speaker plate. Original on the left, trimmed on the right.
Now the speaker fits between the studs, and can sit flush on the inside of the grill.
So now the speaker and the pod mount to the same side of the board. There is still a bit of space between the grill and the speaker.
Now the speaker magnet protrudes just a little bit. But that's OK because...
With the tweeter down, the mid range magnet almost aligns with the body panel hole.
The paper template shows where the magnet projects, near the edge of the body hole.
Just a quick bit of hammer work to ease the lower edge of the hole into the body cavity.
A bit of paint touch-up.
Everything fits, and the speaker magnet does not come close to contact with the body panel. Once I get all the necessary hardware and a few more components, I can mount the speakers for real.
I counter-sunk the holes on the front of the speaker.
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