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Stereo Upgrade: Subwoofer, Amp and Custom Amp-Cover It may look like a mini-mite but, with a new subwoofer, this Mini Cooper gets a mighty thump. From "Tricked Out" episode DTRK-212

	This Mini Cooper S-type gets a thump transplant with an upgraded power amp and new subwoofer.

In this project Andrew Totolos, host of DIY's Tricked Out, upgrades the stereo on a 2003 Mini Cooper S-type with an outboard amplifier, custom amp-cover and subwoofer. After introducing the project car, Andrew begins the project with the removal of the Mini's factory radio.

Materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this project include:

amplifier
subwoofer
speaker wire
line-level converter
amp wiring kit
press-board
pencil
straight edge
2x2 wood strips
standard upholstery supplies
jig saw
cordless drill
tape measure
electrical tape
wire ties
utility knife
wood glue
scissors
spray adhesive
safety glasses

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale. A considerable amount of wiring is involved, as well as removal and replacement of trim pieces, but experienced gear-heads should have no problem with it.

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Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps represent general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

The Project Car

This 2003 Mini Cooper-S packs a punch right off the lot with 168 horses. On this one, custom window-tint and the panoramic sunroof set off the hyper-blue custom paint, and a full body kit has been added. Sixteen-inch wheels, sport tires and a tuned suspension to keep this Mini firmly planted.

Inside, the S-type Cooper comes with a stock six-speed manual box, aircraft toggle switches on the dash and leather interior, all contributing to the cockpit feel.

Up front, the hood scoop pushes cold air through the top-mount intercooler, and the intake air is fed through a custom short-ram system. Spent gasses exit through the upgraded stainless steel dual exhaust.

Removing the Factory Stereo

• Reach under the steering wheel to release the trim panel on the driver's side.
  
  
• Remove the two star-bit screws that secure the top of the left-hand pillar (figure A).

• Remove the first screw on the right-hand pillar. Open the glove box to reach the second screw, and remove it (figure B).

  Figure A

  Figure B

  
  

• Once the screws are removed, close the panels and lift the ashtray out of the cup holder (figure C). Remove the two Phillips-head screws underneath.

• Next, pull off the circular shift-boot trim piece (figure D) and push the side mirror control panel out from underneath.

• Unplug the two side-mirror connections and set it aside.

  Figure C

  Figure D

  
  

• Remove the final two screws inside the mirror control housing and then everything will be ready to come out.

• Lift the cup holder tray up and pull it away from the center console, and then slide both of the pillars out (figure E) on each side.

• To release the stereo there are four star-bit screws that hold it in place. Once they are removed (figure F) the stereo will slide forward so you can unplug the harness and the antenna and pull it out of the car. Be sure to disconnect the negative battery cable before doing any electrical work.

  Figure E

  Figure F

  
  
  
  

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  RELATED PROJECTS: Acrylic Subwoofer Enclosure: Completion Acrylic Subwoofer Enclosure: Glue-Up and Amp-Wiring Acrylic Subwoofer Enclosure: Box Panels Acrylic Subwoofer Enclosure: Prep Work WEB-EXTRA: Online Volume Calculator for Speaker Enclosures

  
  

  ALSO IN THIS EPISODE:
  	Stereo Upgrade: Subwoofer, Amp and Custom Amp-Cover