#1627827 - 04/10/09 12:07 PM
2002 F150--Rebuild
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Foam
Team SoundDomain
Registered: 06/09/08
Posts: 655
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I last competed with my 2002 F150 in/around July of 2007. At the end of 2007 I stripped down the truck with the intention of doing a rebuild that would be just for fun. I started posting here, you can find the old thread, with what I was doing.
In the end I tested a bunch, learned a lot, but didn't get anything that was built.
Well it's time to build this truck and get it back in the lanes. I like competing with the truck. It's mine. It's the vehicle that I got real serious about competition with, and I enjoy driving it. It isn't a traditional show truck. It is a truck. It goes deer hunting--it gets used as a truck.
My goal with this rebuild is to build a vehicle capable of doing 2 seat judging. I understand that a truck is not even remotely the best vehicle to be doing that with. I think I can make it work. I learned a ton during my testing and I think I can make this work.
Equipment wise--some of this is still floating. I'm testing some equipment for people now but I will go ahead and list what I know is going in.
Headunit: Sony Mobile ES HU (old school, I will add model number when I get home. It just slipped my mind. It is the C90 model from the year before the C-90. Basically the same with no fold down face).
Processor: Alpine H701. This is for now. May go home audio later on.
Amps: Genesis P2 ultra--on tweeters
Genesis P4 ultra--bridged to Mids
Genesis P4---Center channel and rear fill 
Genesis PSub Ultra--Front subwoofer
???????--Amps---Rear subs (still working on this)
Speakers:
Front Stage--Incriminator Audio 6 1/2 and tweeter
Center Channel--Audiophile 3" point source
Front Sub: Ultra LV10
Rear Fill: Not sure yet---maybe Ultra components
Rear Subs: Ultra 18" Monster Series (pair)
Deadening/absorption--This truck has been deadened with about eleventy billion products. It has always been my testing ground. So in different pictures you will see everything from Peal N Seal to Schosche to Second Skin. In the perfect world I would pull off everything and just put in second skin. Unfortunately I don't have the time to pull all that off. The floor boards in front of the listeners easily have 10 layers on them. That isn't coming off. All new products will be second skin. All voids in the truck were filled with polyfill. You can see that in the old thread.
Electrical--wiring will be Hooker Audio. It's never failed me and I like it a lot. So it is going back in.
Batteries: Powermaster. Again no failures even though I beat the crap out of them. So I will be using multiple batteries from them.
To start this is the truck:
Truck after 2006 season( a bit of pride):
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#1627832 - 04/10/09 12:20 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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:rock:
fat pothead
SD I eat the big piece of chicken
Registered: 12/04/07
Posts: 7248
Loc: Rochester, Ny
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sounds like it's going to be a fun build.
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#1627833 - 04/10/09 12:20 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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Foam
Team SoundDomain
Registered: 06/09/08
Posts: 655
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Even with all of the testing, I still learn stuff everytime I work on a vehicle.
My initial thought was to put my midbass in the kickpanels and vent into the kickpanel itself. So the emergency brake was removed, all wiring moved, and the hole in the metal opened up. This was all shown in the old thread. I built off of that:
Speaker flat against kickpanel. test fitting
Wanted some angle to it. Need this speaker to play up into the low 3khz range, so it didn't need to be totally off-axis:
This is me getting some angle on the kick:
Notice that hole in the floor---don't forget it, I'll come back to it later.
Fleeced in the gap. Stretch fleece, cover in resin, let dry. Simple process:
Then fiberglass the entire thing for strength. I think I added between 7-10 layers of mat:
Picture of the roughed fiberglassed passenger side next to the driver's side before glassing started:
Speaker all fiberglassed and secured to the vehicle:
Some modeling clay added on the inside for deadening:
A second skin deflex pad was added behind the speaker--no picture.
Incriminator Audio 6 1/2" in the pod and the entire thing deadened over:
Driver's side. It was the same process.
So with that far, I decided to hook it up and let it play a bit. Just to not get to far down the road.
What did I discover? That the drivers put out a good amount of midbass. In doing so they are causing the metal up inside the body of the vehicle to resonate--BADLY. I can feel it with my hand, but I can't get to it without taking the dash out. This was causing some serious issues with the lower midbass frequencies.
F me. So that won't work. Remember that hole in the floor. That is where the last time I competed that I vented my mibass through the floor. I had a 3 way system back then with the mids and tweets on the dash. I tested just before that came out and the truck did two seats with no time alignment with those pods.
So I will be rebuilding the kicks and using that hole as the vent. I know it works, it worked in the past. It just won't be as stealth as these would have been. Sound over stealth though.
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#1627855 - 04/10/09 12:55 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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Foam
Team SoundDomain
Registered: 06/09/08
Posts: 655
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Center Channel:
I have a friend named Andy Otwell. He works at a store named CKR in Prattville, Alabama. Years ago he was building a truck very similar to mine. It was more of a demo vehicle than anything else. He put a center channel in it. I asked him where the room came from and he told me there was a hole in the top of the dash if you removed the trim that was perfect for a 4" driver.
So I went in search of said hole. Here it is: 
Dirty windshield:
Testing speaker in it (this is just a test speaker, not the one I will be using):
Next step was to put some tin foil down into the hole as far as I could get it in every area:
Then some fleece. This fleece was left over from Thumper's feety PJs he made for himself. He sent me the scraps  :
Coating the fleece with resin:
*Insert TV Time*
Fleece dried, and popping the piece out:
Trimmed up and test fitting back in the hole:
Trimmed up again, this is what I had:
I need to upload some more pics--back in a few 
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#1627879 - 04/10/09 01:40 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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Foam
Team SoundDomain
Registered: 06/09/08
Posts: 655
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Ok, I apparently forgot to take some pics.
I made a baffle for the speaker, then trimmed down the enclosure the height of the baffle. Then fiberglassed the baffle in place. I also added a layer of mat fiberglass to the inside of the pod and to the outside of the pod (couldn't add more than a layer outside because of the extremely tight fit of the piece).
This is the pod after those steps:
Test fit back in truck:
Looking into the radio cavity (that area was 'trimmed' to fit a double din years ago):
Test fit with radio and dash piece back in place (to make sure everything fit):
The pod painted black and the top carpeted:
Wire coming out of pod:
Lamb's wool in pod:
Pod with speaker sitting in it:
Marking the dash trim piece for the grill:
Screws holding the pod in place. Seriously I don't think it would have moved with no screws it is such a tight fit, but just to make sure of no shifting at all--it has 4 screws going into it:
Final picture of it:
Still to do:
1. Mount real speaker in it.
2. Make grill
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#1627885 - 04/10/09 01:53 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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Foam
Team SoundDomain
Registered: 06/09/08
Posts: 655
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the plan is to have a subwoofer in my center console for SQ listening. I have an Ultra Subs LV10.
I had thumper run the T/S on the sub through his box building program and he came up with this:
The yellow is 0.4 cubic feet, the orange is 1.2 cubic feet, and the red is 0.2 cubic feet. He informed me that the yellow and orange both assumed a 6ddb boost at 50hz due to cabin gain. I asked him to take it out, and this is what he came up with:
red is .4 cubic feet and yellow is 1.35 cubic feet.
I still don't understand how removing a 6db boost at 50hz has such a dramatic effect at 20hz. basically I decided I didn't trust the program and would go to what I did trust.
This is my test enclosure. It was built for a 12", so I used a filler panel to use on the 10".
All nice and mounted in the enclosure:
In the vehicle:
I will test it firing forward and backwards. I will also lower down the available air space until I like how it sounds. Then I will build the enclosure to that size. Good times.
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#1627886 - 04/10/09 01:57 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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Foam
Team SoundDomain
Registered: 06/09/08
Posts: 655
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While working on the truck last night, I looked behind the seat and found this:
That's one big sub
here is a comparison between the Ultra Subs Monster 18 and the Ultra LV 10:
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#1627930 - 04/10/09 04:59 PM
Re: 2002 F150--Rebuild
[Re: Foam]
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keep_hope_alive
in another life, i'm a serial killer
SD I Power Bombed the Undertaker
Registered: 04/24/07
Posts: 13370
Loc: Quad Cities, IL
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damn, that 18 is huge!
nice center channel enclosure Andy. very cool.
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#1628291 - 04/11/09 09:33 PM
Re: 2002 F150--Rebuild
[Re: keep_hope_alive]
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IamMurph
Retired
[ADMIN]
Registered: 10/30/01
Posts: 35559
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I though the 10 was beefy. That's a huge biatch.
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#1629474 - 04/14/09 10:16 AM
Re: 2002 F150--Rebuild
[Re: IamMurph]
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93_chevy
fabricator
Member
Registered: 07/01/02
Posts: 3538
Loc: San marcos, TX
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looks good and im sure it will sound excellent
your FG'ing skills need work though
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