2018 Audi S5 Build Log – System by Steve Cook at Audio X

[mumbles]

Any reason acrylic?

Steve basically said that acrylic is virtually indestructible and make for a stable mounting surface...

[mumbles]

Time for updates;

[mumbles]

Delete

[mumbles]

Starting this update with some awesome wiring...



Doors with sound deadening and acrylic rings...




Oh, and speakers... we have speakers!

[mumbles]

And now, the trouble-makers!!!
The first picture is the factory midbass speaker (hard to see) which fires toward the back of the door and is directed into the cabin by the opening. The whole contraption fits in the 8" diameter door opening... why Audi/B&O didn't just use an 8" diameter speaker is beyond me! The second pic shows the real problem. For some stupid reason, when Audi created a grille for the speaker, they chose to seal the area over the speaker while leaving the vent area open... half of the grille passes sound and the other half doesn't!?!?



This brings me to the third and fourth pictures which show the PITA work that Steve has had to perform... essentially, grinding down the sealed up part of the grille to get it opened back up. The problem is that the plastic is so soft, it is melting and sealing itself back up... causing Steve hours of slow, unnecessary grinding all due to a bad design/implementation. Ok, I'll stop my ranting!



I'll close this update on a happier note...
A little sneak peak...

[Hillbilly SQ]

I'm guessing Steve is gonna just custom make new door grilles? That is an idiotic design on Audi's part.

[mumbles]

I'm guessing Steve is gonna just custom make new door grilles? That is an idiotic design on Audi's part.

At the moment, his intent is to use the factory grille. He'll get it ground down correctly, I have no doubt about that!

[mumbles]

Here's a couple of shots of the IB framing that Steve had welded up to mount the subs to the car...



A little CNC goodness... 3 layers of Russian Birch!





The subwoofer grille design Steve came up with... Love it!

[chithead]

At the moment, his intent is to use the factory grille. He'll get it ground down correctly, I have no doubt about that!

I had that same issue with the Challenger, but on the dash. Wanted to keep the factory panel, but it only had a 3" round circle cutout, even with this ginormous detailed grille section on each side.

Used a sander to grind down as much material as possible, but then a Dremel and hobby knife to carve out each slit. Took FOREVER. But totally worth it in the end.

[mumbles]

I had that same issue with the Challenger, but on the dash. Wanted to keep the factory panel, but it only had a 3" round circle cutout, even with this ginormous detailed grille section on each side.

Used a sander to grind down as much material as possible, but then a Dremel and hobby knife to carve out each slit. Took FOREVER. But totally worth it in the end.

I can't imagine the shear tedium of grinding that much plastic... and always being worried I'd go to deep... (thats what she said!)