It's starting to look like a subwoofer box everybody!!! Here's the result of nearly 10 hours of footage and 3 weeks of editing... Thanks for following the build and slappin' big ole thumbs up 👍
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1: Exposing How Foam Reacts
- Showing detailed examples of how expanding foam holds up over long periods of time, both outdoors and indoors.
2: Flattening Remaining Foam
- The upper roof sections get trimmed and sanded flush for a perfect fit when installing wooden squares - adding more spray foam to fill any small holes underneath.
3: Attaching Inner Roof Squares
- Filling in the steel cage (roof) with two layers of 3/4" plywood. Clamping wood into place using self tapping metal screws and scrap pieces of mdf + birch.
4: Cutting Inner Roof-Brace Squares
- All factory roof braces reinforced with steel tubing welded directly against the beams, then filled with 1.5" wood to add even more strength.
5: Reducing Foams Thickness
- Making great stuff layers exactly the correct height so final row of roof squares can mount properly while still being cut flat.
6: Affixing The Last Roof Squares
- Securing angled roof piece and complete front row with screws and adhesive. This wraps up upper section of steel cage for now.
7: Testing Panel Flex & Noise
- Showing how LOUD the van is without any deadener. Knocking outside body panels to illustrate flexing and noises of vibration. Echo effect inside the van gets extremely noisy. The thumps and bumps reverb throughout the entire vehicle like a big drum riding down the road 😭
8: Explaining Polyurethane Foam
- Running through process of how to use 2 part closed cell urethane foam from US Composites. Mixing parts A and B equally to yield very strong material.
9: Finding & Covering Holes
- Every car, truck or van has hidden spots where not 100% sealed. These important areas get covered with Gorilla tape & silicone. This prevents any liquid from spilling out before it fully expands.
10: Preparing For Sound Deadening
- Inside paint gets sanded to expose bare sheet metal. Cleaned with alcohol for Damplifier Pro to deaden and stick at maximum level.
11: Applying Sheets of Deadener
- Choosing best places to apply sound dampening material. Also doubles as automotive insulation for high and low temperatures. Also helps beef up the body panel for less chance of warping from concentrated expansion behind the walls.
12: Sanding Deadeners Surface
- Taking the decorative black surfaces off the tops. Increasing effectiveness of foam bonding. Strong bond = must have!
13: Adding Foam to Empty Cavities
- Mixing and pouring liquid foam into key spots. Filling voids completely with each additional application. Mix parts equally, stir very fast for 25 seconds, then pour out into position and wait for expanding to start.
14: Covering Flush-Cut-Foam & Holes
- Rolling another layer of sound deadening directly over the freshly filled gaps and voids. Foam is cut flush with factory holes then covered with a sheet of deadener to hide everything.
15: BEFORE AND AFTER RESULTS
- Amazing knock test result,listening to the annoying rattle-like before knocks, and the rock solid tank-like after. Great comparison to see and hear the huge difference it made.
16: Plumbing Thru Electrical Pipes
- Fitting cell core abs between the walls for a lightweight conduit solution. Couplers used to join multiple segments. Also much lighter than pvc pipe. This will house all sorts of accessory wires for switches, lights and relays.
17: Resizing First Side Row
- Using chop and table saw to resize lower squares of the driver side. 1st part of the makeshift dam.
18: Screwing In Bottom Row
- Drilling self tapers into the 11 gauge flat bar steel, holding the 1st layer of wood firmly into place with PL MAX and PL8x.
19: Filling Remaining Voids
- Working from the bottom upwards, slowly reinforcing and filling the empty space behind the cage, adding another row of squares then filling more, ect
20: PROGRESS RESULTS
-Demonstration how each layer changes the way it sounds.
21: Preparing Roof For Final Liner
- Taking down any high rises in material on the roof with a power sander. Ensuring the last piece of wood that lines the cage sits smoothly against the surface.
22: Affixing The Last Liner Pieces
- Propping up and screwing the first large wooden sections onto front. Box is seemed in the middle because 5x10 plywood is too hard to find.
Music By: YouTube Music
Licensed under a Creative Commons Attribution license (https://creativecommons.org)