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Nissan 300ZX: Motorized Subwoofer Enclosure and Amp Rack Andrew Totolos outfits a classic Z-car with a Batmobile-style compartment for a subwoofer and amp. A mechanical actuator drops the audio components out of sight when not in use. From "Tricked Out" episode DTRK-404

(Continued from page 1)

	The sub box, fascia and amp rack are all constructed from MDF.
	The tilt of the amp rack will be controlled by a mechanical actuator.

Custom Subwoofer Box: Design and Materials

The sub-enclosure project gets underway with the creation of a fascia board and box from MDF (medium-density fiberboard). Andrew wants to sink the sub box into an area in the trunk and make it flush with the sides of the trunk compartment. To do this, he creates the fascia board into which the sub box can be recessed.

The fascia board, cut for a custom fit the rear of the Z, provides a level surface supporting the speakers and amp and create the backdrop for a "flush" design. This design will allow the speakers and amp to be concealed when not in use, then brought up for optimal listening placement (and visual flash) with the touch of a button.

The sub-box itself is a simple rectangular box, large enough to accommodate the speakers and offer them sonic "breathing room." It's also fashioned from MDF.

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The 300ZX is a solid well-built sports car — with enough aftermarket parts available to make it sought-after among the tuner set.

Materials and tools used in this phase of the project:

cardboard
utility knife
medium-density fiberboard
jigsaw
table saw
router
wood glue
brad nailer
standard shop tools
woodworking tools

	Figure E
	Figure F
	Figure G Andrew uses a hand-held router to smooth the edges of the fascia board.

The first step in designing and building a setup like this one is to check out the space you have to work in. In order to have enough room for the sub box to fit in the rear compartment of the ZX, Andrew removes the spare tire.

Sub-Box Fascia Board

• Andrew uses the carpet from the trunk to make a template to determine the size of his box. He wants to make the box a little bit smaller than the carpet, so he traces around the carpet and makes a cardboard template (figure E).

• Andrew test fits the cardboard template in the car, and he trims any edges that don't fit properly. It's much easier to make a square box than one that conforms to the contours in the trunk. Andrew measures how big of a box he can fit in the trunk.

• Andrew traces the cardboard template onto a sheet of medium density fiberboard, also known as MDF, and cuts out the shape (figure F).

• Once the piece has been cut down to size, Andrew uses a hand-held router to round off all the edges so the wood won't damage the interior of the car (figure G).

• When the fascia board is ready, Andrew test fits it in the car. He also measures how high it needs to be to sit flush with the hatch floor.
  

• Andrew uses a table saw to make the straight cuts for the sub enclosure (figures H and I).

• Once the box pieces are cut, he uses the edge of the workbench as an aid to hold the pieces at a right angle while he runs a bead of wood glue along the first edge and tacks the box together with brad nails.

  Figure H

  Figure I

  
  

• The remainder of the box goes together easily (figures J and K).

• When it's assembled Andrew uses the router to round the corners off the box.

  Figure J

  Figure K

  
  

  Figure L

• Now it's time to take the assembly to the car for a test fit.

• With the box in place in the car, Andrew sets the fascia board on top and temporarily screws them together (figure L) so he'll know the alignment is correct when he removes the pieces from the car.
  
  
  

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  ALSO IN THIS EPISODE:
  	Nissan 300ZX: Motorized Subwoofer Enclosure and Amp Rack