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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 2)

Andrew secures the framework for the amp rack.

The sub box has been constructed, and now Andrew wants to make the new addition even better by adding a motorized panel that will pop up to expose the amp and a set of six-and-a-half-inch speakers, which will blast the mid and high frequencies.

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Figure M

Custom Subwoofer Box: Pop-Up Panel and Amp Rack

Materials and tools used in this phase of the project:

table saw
screwdriver
router
masking tape
jigsaw
piano hinges

Sub Box: Pop-Up Panel

For the motorized panel, Andrew cuts the fascia board at the appropriate place so it can be configured to "pop up" in the rear compartment of the Z.

The small speakers and the amp will be mounted on the front of the panel so that, when raised, they'll create a better "sweet spot" for the listeners and be visible inside the car.

	Figure N
	Figure O
	Figure P

• Andrew marks a line for the hinge along the joint where the fascia meets the sub box, and cuts the fascia board along the line using the table saw (figure M).

• He reattaches the rear section of the panel to the sub box using the existing screw holes so that everything will line up correctly in the car.

• After the fascia panel is screwed in, Andrew uses the router to round off the front edge to make some clearance for the piano hinge.

• He tapes the hinge to the panel to hold it secure so it doesn't move as he screws the hinge into place.

• The new subs come with templates that make marking the round holes in the box easy.

• Before he cuts out the speaker holes, Andrew adds a few drywall screws to permanently attach the fascia board to the sub box (figures N and O).

• For cutting the speaker holes, Andrew drills a few starter holes to get the cuts started, then cuts out the holes using a jigsaw (figure P).
  

  Andrew secures the sub-box to the fascia.

  A piano hinge enables the panel to pop-up.

  
  

  	Figure Q
  	Figure R
  	Figure S

Once the speaker holes are cut out, Andrew uses a piece of scrap MDF and gives his amp rack idea a test run.

• The amp rack can only be as wide as the space between the struts in the back of the car.

• Andrew cuts a smaller front panel on the table saw and gives the amp rack another try.

• Next, Andrew trims out the bottom corners of the amp rack to give it more clearance in the car. He traces the outlines and cuts the smaller speaker holes for the six-and-a-half inch coaxial set of speakers (figures Q and R).

• The amp rack will have to sit against the bottom of the fascia board at an angle, so Andrew builds a gusset — or brace — to hold it at a proper angle.

• Andrew reinforces the sides so it will stand up to automotive use, and he attaches it to the back of the amp rack panel (figures S and T).

• To complete the rack, Andrew adds a couple of decorative trim panels on the ends to hide the midrange speaker wiring.

• Andrew then attaches the amp rack to the bottom of the fascia board (figure U), and secures the entire component to the sub box with the other side of the piano hinge.
  

  
  

  
  

• The box is too big to go into the car in one piece, so Andrew removes the screws that hold the big pieces together before he takes it to the car for a test fit.

  Figure T

  Figure U

  
  
  
  

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