Author Topic: custom door cards for aftermarket speakers (pic heavy)  (Read 3052 times)

PhoenixAutosport

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custom door cards for aftermarket speakers (pic heavy)
« on: 22:05, Sun 08 July 2012 »
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Had a customer send in some renault 5 door cards for refurbishment and a bit of modification so that he could fit his aftermarket speaker grills into them instead of the original plastic grills.
thought that it may be of interest to some so here are a load of pictures of what i did to them  :D

1) these are the grills that the customer wanted fitted into the door cards


2) lower edges of the cards had a fair bit of water damage so section at a time they were clamped flat and painted with a thinned resin so that it penetrated the card and then set in the correct flat shape


3) cracks and surrounding area impregnated with cyanoacryalate to restore original strength


4) again area impregnated with cyanoacryalate to restore original strength


5) this area had 2 cracks, distortion to the shape and a missing fixing so it was clamped in place for teh repairs to be done


6) area surrounding cracks and where the fixing was missing were soaked in cyanoacryalate, fixing was then clamped in place to set


7) bolster on one side had started to collapse but damage was only in the surface layer of the card with the main structure being intact


8) cracked area set with resin to prevent any further cracking occuring


9) to mount the aftermarket grills i cut some rings from mdf sheet


10) mounted the mdf rings in the back of teh door cards so that they sit slightly below the level of the normal speaker aperture


11) view from the top, speaker grill tabs were already missing so it saved me a job removing them :)


12) edges of the speaker holes had seen better days and were crumbling


13) edges soaked with cyanoacryalate to make them good and solid


14) edges sanded down and filled as required to restore shaping


15) blocks fitted to the back of the rings to give something substantial for the grills fixing screws to fit into


16) close view


17) speaker grill surround trial fitted, internal edges refinished as required


18) refinished edge


19 close view with surround in place


20) cards coated in a layer of thinned epoxy, this soaks into the surface ensuring good adhesion and allows refinishing of the card surface to improve the quality of finish


21) surface refinished


22) close up of speaker area after refinishing


23) door cards flocked
















24) with the aftermarket grills fitted










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Ash-Lee

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Re: custom door cards for aftermarket speakers (pic heavy)
« Reply #1 on: 22:27, Sun 08 July 2012 »
Damn.

They look good.  8)

hughesrobert13

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Re: custom door cards for aftermarket speakers (pic heavy)
« Reply #2 on: 20:47, Sun 19 August 2012 »
got to be fair mate they look great what sort of money would it cost to have these done ? no modifying just as standard items cheers rob
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