The Black Nasty - AQ Rebuild 2012 season!!!!

Got a case of F26 Construction grade adhesive, this stuff is amazing, used it in dozens of builds.


Got two layers of 3/4 mdf at the top and used my new Kreg Pocket jig, that thing is awesome.


A small piece of 1/2 mdf attached to the roof with f26 and pressure, then as picture piece of 3/4 birch ply.




Done for today, trimmed the headliner some more, 2 layers of 3/4 mdf on the back wall. It is rock solid.

Got the floor finished, bolted in to the floorpan and 2-3 layers thick in most places.



Also got the speaker wire ran under the box and will be hidden into the wall.

Sides, floor and back wall done for now.

The back shell is just about finished just body work and fiberglass with a few small 45s is left then primer and paint.

Here is one of the top 45s

More updates, here is some corner work, back small 45.



2.25 inch radius PVC corners FTW!!!!!

Got almost all the body work done, all screw holes are filled and 45s done, just glass work left.



Before


After






Before


After - Passenger side


After - Driver side


Glass work on the two 45 corners then more sanding next!!!!

My little one wanted to see how the club house was coming along so I let her check it out lol.

Group shot of the power plant - 4 AQ3500D.1s





With Toolmaker Copper Dual inputs FTW!!!!!






Next on the list is finish the inside of the shell of the wall!!!!

Here is a diagram for my wiring options for the amps, both options look great!!!

looking good keep pics coming!!!!! any more updates?

Yeah just haven't had time to move them over here yet from smd, I plan on working on it some more in the next few days all glass work done just about ready for paint.

Started fiberglassing the inside of the wall and coating with resin. Also show a trick I use to keep the chop mat as tight as possible to the surface while you lay down resin.

First layer chop mat



First layer done



3 layers later.....ROCK SOLID!!!!



Passenger side done, sides, back, and roof resined.



Driver side done.




******Now here is how I keep the mat tight to the surface and it will hold there no matter what direction it is placed. Notice is says HEAT resistant, this is key with fiberglass!!!!



Spray this stuff down into the area you want to attach some mat.



Lay the chop mat press into the location, wear gloves this is some aggressive spray glue lol



Resin applied nice and tight fiberglass job there!!!!



Here is where I quit for the night, start sanding in about 8 hours.

Ready to start sanding fiberglass and getting this thing smooth. First tape off interior with seats and center console removed.



Turn on squirrel cage fan and shop fan to keep air moving in this 100+ degree garage.



Prep exposed skin so I don't die from fiberglass sanding, coated in baby powder and glove taped up.


Suit up for the pain of sanding fiberglass. Ready to GO!!!


Started on the drivers side first took 1 hour to get that corner done.



Took a break then finished the rest, took another 2 hours, 36 grit pad on a 3M 5/8 throw DA.


Ready for rage xtreme, my bro in law sanding the roof with 100 grit.



Driver side done



Passenger side done





Thru some cheap primer on to see if I missed any spots, looks great.







To get to here took 10 hours worth of sanding.

Then later that morning decided to put my Add a leaf on the truck.


Add a leaf in the middle.



Sits like a truck again, just need front springs next!!!

Update 8/4/12 - Port and Shell Primed

Got the port wall in place and smoothed out.




Then time for finish sanding before primer, took hours and hours of sanding, lil helper having fun playing.


Doing WORK!!!!



Teaching her how to sand.


Baby girl doing WORK!!!!


Baby girl in the port...

Now these next pics are where it starts to get serious...

Truck completely masked off





Interior of shell primed







Masking removed









Wonder what this could be for? Called Lemon Glow



More to come soon!!

Start preping wall shell for paint, block sand the primer and fix any issues with filler or primer.

Truck masked off




At one point there where 3 of us in the shell at the same time sanding, dust hurricane lol.








AND THEN,,,,,looking inside the port after base coat.








*****NOTE any dark spots you see thru the base coat that is primer where areas had to be fixed, I wasn't about to go get more of this base coat cuz it costs alot $275 a quart, and you wont see any of that on that side any ways, port is perfect and that was the goal.



Me mixing clear, 1/2 gallon worth sprayed on interior of shell total.



After cleared it was about 10 pm so color looks different with flash.

The next day, right before buffing and wet sanding and waxing....














Then we wet sanded with 2500, cut with rubbing compound extra cut and waxed with ICE wax, the camera can't catch the difference so it is one of those has to be seen in person type things, BUT that means shell is finished!!!!

Later that night at wal-mart getting some supplies for door panel fab work.

YOU MAD AT THIS???? DERP!!!!!

Door panel fab for highs amp AQ120.4












That is where I stopped 2 am Monday morning, more glass work ahead!!!

Update 8/17/12

Door panel fab rear door

Got the panel all stripped down and stretched some fleece out over just the section I needed. Taped off the rest of panel while coating with fiberglass and resin.



Fiberglass just back for reinforcement





Knocked the high spots down with 36 grit and shot some cheap primer on.



Front side smoothed out




Did the remained glass work, notches that needed to be done and cover the door handle pocket up.





High spots knocked down again and more primer applied.



Smoothed out and ready for test fit.

Continued

Test fit on the truck, looks good.





Clearance at top of panel with door fully shut.



Rear of panel notched for additional amplifier clearance.



A few inches between door panel and where amplifiers will be, plenty of clearance.

Continued

Showing my little one how to "see" with your hands since your eyes will always lie to you. Looking for high and low spots.



She was showing me where they were at.



Laying down some RAGE, notice she is on the dry side now, just give it a sec lol.



Spreading the filler, little one is sneaking up on me.



And BAM her little hand in the fresh filler and my wife laughing while taking the picture.



Where I stopped for the day.

remembering why I hate sanding filler by hand. Anyway about ready for paint.

Update 8/26/12

Rear Door panel glazed


Pin holes sanded out


Guide coat sprayed




Filler primer sprayed via HVLP gun





Driver rear door started


Fiberglass and everglass added


Guide coated applied after filler and glaze.


Top notch started


Fiberglass started


More guide coat and sanding


Filler primer sprayed with HVLP gun

Continued
Base Coat sprayed on passenger rear panel - Called Carbon Flash


Clear Coat sprayed





Installed after wet sanding, cut, buff, wax.






***Note I am going to put black carpet in the bottom pockets on both panels when time permits, not a priority at the moment.

With the door shut, look at that reflection yummmm......



Driver side wet sanded



Installed

Continued
Front Baffle started.....getting serious.





Sub layout 6 15s



Sub holes cut for first layer.



More to come next weekend!!!