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Ice Ice Polo Robolop Design


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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†01, 2012 at 7:27 AM / IP Logged Link to Post Post Reply Quote robolop

Like I pronounced earlier in my BMW topic, we bought a new VW Polo.

This will be used for daily use, and most of the time, my wife will drive it. When we made the decision to buy a daily car, I had to make a promise that I wouldnít lower it, or put bigger wheels on it.
First of all, because she has troubles with her back, and for the rimsÖ.it wonít be long until sheíll drive up the sidewalk.
But as for the ice, she had no problems with me doing some ďadjustmentsĒ, BUT there had to stay enough room in the trunk at all costs.

The Polo is a 1400 comfortline, with DSG, Airco, Assheating, Cruise Control en some other stuff.

Here a picture from the Polo, just delivered (still with the protective foil on)

Ice Ice Polo Robolop Design -- posted image.

I will take some more pictures once sheís washed, but there not much to be seen. Itís an original new car.

But maybe some carbon updates will happen, who will knowÖ

About the ICE, everything I need is already here.

As for the radio, Iím going to keep the original one, but since Iím going to use an amp, Iíve bought a Pac-Audio interface.

Ice Ice Polo Robolop Design -- posted image.

Iím very happy I didnít sell the Precision Power amp I wanted to mount into the bimmer first.

Ice Ice Polo Robolop Design -- posted image.

This PPI Deq 230 is a 30band equalizer. I can screw demount the front from this device, and with the longer cable (which is in the box), you can change the settings behind the wheel.

Ice Ice Polo Robolop Design -- posted image.

As for the Subwoofer, I chose for the 4 Focal Utopia 13ws , again

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Also the front speakers will be Focalís: the KrX3 series

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

The filters.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

And I also bought some cables and damping materials.

Ice Ice Polo Robolop Design -- posted image.

Itíll take a while before Iím going to begin on the install. First of all I want to finish up the mounting works from the new radio, in the bimmer.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:12 PM / IP Logged Link to Post Post Reply Quote robolop

Finally , I started on the Polo.

I searched the net to find some pictures of what could be hiding behind the carpet, but then I decided to take it all out anyway. Sooner or later, this was inevitable.

The spare wheel, well, that has to stay. The intention is that this stays easily accessible, in case we need it.

In other words, Iím going to make this install so that, in case of a flat tire, my wife can take the wheel easily and safely.

Ice Ice Polo Robolop Design -- posted image.

†On the right side you can see thereís not much that can be done here.

Itís the place of the petrol tank, Iíd better not cut this open do I ?

Ice Ice Polo Robolop Design -- posted image.

†On the left side Iíve got some more place to work with, but ho wand what, Iím not quite sure.

Ice Ice Polo Robolop Design -- posted image.

Then I placed a piece of MDF on the bottom, and looked what kind of emplacement is possible here.

I was at first a bit disappointed there wasnít enough room, cause in my case, you canít have enough room!

The intention is that the sub-box is placed against the rear seats. This will be in favor of the pressure, and also the looks will be much more pretty.

Ice Ice Polo Robolop Design -- posted image.

What I do know is that Iíll place hem under diagonally. The view will be more spectacular and more beautiful, I think.

†About the PPI (amplifierŗ), Iíll have enough space to work away the cables in an appropriate way (L and R)
The equalizer is something elseÖThereís no room for that. You can see that I got it out of its housing, and I placed it ON the amplifier. It looked OK in my opinion.

†But Iím not there yet. First of all Iím going to calculate how many liters are necessary for the subbox, the rest will turn out from its own.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:16 PM / IP Logged Link to Post Post Reply Quote robolop

Because the floor needs to go all the way up before you can access the spare wheel, I had to make a hinge first.

So I started to saw 2 little alu plates of 10mm thick.
Then I screwed them together and drilled 22mm holes in them.
These holes I oppressed with a lager of 22mm.

Ice Ice Polo Robolop Design -- posted image.

ďOppressĒ sound really professional, but I did it quite simpleÖ

As you can see, I placed the plate between the bench. After that I took a cap, which was a bit smaller than the lager, and then I turned it all together. Simple

Ice Ice Polo Robolop Design -- posted image.

The result.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

The alu plates will be mounted on a bracket, which is already in the polo (from the factory)

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

I screwed a bolt through the lager, an M8.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Once I did this on both sides, I connected these 2 with a U

Ice Ice Polo Robolop Design -- posted image.

This U is on the inside 18mm. There Iíll place the wood in.

You can also see that the wood will be placed diagonally

Ice Ice Polo Robolop Design -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:17 PM / IP Logged Link to Post Post Reply Quote robolop

This will be the box, that will be mounted in the trunk.

Ice Ice Polo Robolop Design -- posted image.

The 4 holes you see are for the Focal subs (4x13cm).

Another look at how big the sub-box will be.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Now you see a MDF-shelf that will part the sub-box from the amplifier area.

About the partition, Iím thinking on some cool things, but Iím not entirely sure yetÖ

First I had the idea to work in the equalizer in one of the sun-blinders on the seiling, but they were too big for it. Itís a pitty, cause I† liked the idea myself.

Now Iíve been working on the amplifier, and the more I see it, the more it grows on me.
Iíll have to make a new sort of high-tec bracket, but that shouldnít be a problem I guess.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Here you can see itís possible that I raise the equalizer a couple of more cmís, and that too I liked!

Ice Ice Polo Robolop Design -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:18 PM / IP Logged Link to Post Post Reply Quote robolop

As for the finishing inside the box, I chose 2mm thick aluminium.

I also let some folding work done, which is strong.

Ice Ice Polo Robolop Design -- posted image.

Milled out the holes for the subwoofers.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Mounted the speakers for the first time.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

4 in a row

Ice Ice Polo Robolop Design -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:18 PM / IP Logged Link to Post Post Reply Quote robolop

Because Iím going to mount the equalizer onto the amplifier, I decided to make an aluminum plate.

First of all I drew out everything on a piece of MDF, 8mm thick.

The MDF will serve as a mold for the actually alu plate.
Here you can see how I started.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

The piece is finished, and Iím happy with the result.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

I sawed out the alu plate with the jigsaw, after that I taped it on the MDF.

Ice Ice Polo Robolop Design -- posted image.

Then I started to mill this with the copymill.

Ice Ice Polo Robolop Design -- posted image.

The result:

Ice Ice Polo Robolop Design -- posted image.

I just need to sand the edgesÖ

Ice Ice Polo Robolop Design -- posted image.

Then I mounted the EQ on there with 4 screws, and layed it on the amplifier.

Ice Ice Polo Robolop Design -- posted image.

The busses wonít stay as in this setup. Iím going to let some made on the height I want.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Here you can see the amp also stand on ďbussesĒ. I did this to work away the cables.

Ice Ice Polo Robolop Design -- posted image.

For the first time, I timed how long I worked on this Aluminum plate.

Drawing on MDF

Mill the MDF
Saw the Alu
Mill out the alu
This all took me about 5 hoursÖ

But as you guys already know, I donít give a f*k how long it took me, as long as the result is OK for me

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:21 PM / IP Logged Link to Post Post Reply Quote robolop

Here you see what Iíve done to work away the cables in an easy and fast way.

Close to the bottom of the amp, I made 2 oval holes (L and R)

Ice Ice Polo Robolop Design -- posted image.

On the bottom side I milled out a big sloth to place the cables in.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Once I placed the cables there, Iím going to screw a thin plate on there so the bottom side will look descent too.

Ice Ice Polo Robolop Design -- posted image.

I chose glass to work out the separation between the sub-box and the amplifier.

The glass is hardened, 12mm thick.
I chose this solution, so it will maybe look bigger, cause itís all in one space.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

I milled out a ditch on the left and the right.

Then I let someone bend me a lip on the alu of the amp and subbox.
The glass rests between them. Offcourse Iím going to kit it all off when the subbox is closed.

Off course I need to have some material left and right to screw the box tight.

This Iíll solve by glueing an aluminium bar against the glass.

Ice Ice Polo Robolop Design -- posted image.

Here you can see that this bar is also tightened left and right.

Ice Ice Polo Robolop Design -- posted image.

In that alu I can tap screwthread to screw my cover on. On the side Iíll place long woodbolts and on the back (hinge) I need to straighten it out with polyester, then itís possible I also tap in some screwthread.

Ice Ice Polo Robolop Design -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:21 PM / IP Logged Link to Post Post Reply Quote robolop

I changed the plate which is on the amplifier. I widened it a bit more.

I also added a second plate underneath it. Iíve done this to give it a more tough look.
The sides of the thick plate will get polished, and the thin plate will be sprayed in black.

Ice Ice Polo Robolop Design -- posted image.

On the sides I foresaw other plates with fine openings.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

About those openings, this will provide some more cooling for the amp, and off course look even† better.

You can also see that the plate is placed on 4 rubbers, ON the amp.
On the outside I will add 4 alu busses, but need to let them make first.

Ice Ice Polo Robolop Design -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:22 PM / IP Logged Link to Post Post Reply Quote robolop

This time I wonít be working with copper for the connection of the Focal Subs. When I started this project, I said I was going to keep it basicÖ.and Iím getting the feeling itís getting a bit out of hand again .

I want to show with this connection , that you can make beautiful and good things with simple stuff.

First I let a friend make me a couple of aluminium busses.

Ice Ice Polo Robolop Design -- posted image.

Then I took an aluminium rectangular bar from 10mm on 15mm.

Once I perfectly measured where the holes need to be, I drilled all holes with a pillar drill machine.
This was for me the best way to drill the holes STRAIGHT.
Then I taped a lath in the subbox, and drilled the holes into the wood.

Ice Ice Polo Robolop Design -- posted image.

You can see, that I when I drilled a hole, I let the drill stay into the hole. That way the lath canít go anywhere, and it all stays on 1 line.

Ice Ice Polo Robolop Design -- posted image.

Here you can see the alu bar, with the busses underneath.

Ice Ice Polo Robolop Design -- posted image.

The bar is mounted on 3 places with normal inbus-screws, which are sunken in. These inbus-screws you will see everywhere in this install.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Where the connection of the speaker will come, you can see holes of 8mm. Here will a little anodized aluminium tube will be placed, where the cable will run through.

When you look closely onto the picture, you can see I made big holes on the backside, and provided them with screwthread. Here will come an adjusting screw of M4 onto the little alu tube, so itíll keep itís place. And be doing this Iím sure that it wonít go vibrating cause of the subboxí pressure.

Ice Ice Polo Robolop Design -- posted image.

I need to order the alu busses cause they arenít in stock.

Theyíll be delivered next week.

I also hope that the temperature will go up a bit, cause where Iím working now, thereís no heating. And for those little works, itís freeeeeeezing on my hands (and the rest)

Ice Ice Polo Robolop Design -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:23 PM / IP Logged Link to Post Post Reply Quote robolop

I grabbed the mill from out the cupboard and started making some sloths on the bottomside (for the cables from the subs)

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

Then I started making frames where the glass will rest on. This alu plate is about 3mm thick.

Then I sanded it down, and drew it out.

Ice Ice Polo Robolop Design -- posted image.

Then I cut away as much as possible with the jigsaw. Because itís impossible to saw straight with a jigsaw, I milled the last mm.

Pretty easy to do.

Itís superimportant that the aluminium is taped to the table. I did it with dubbel sided tape.

You can also see that the plate is laying against some nails. I knock them qual to the top of the plate, so the mill doesnít flip when I go over them.

Ice Ice Polo Robolop Design -- posted image.

Ice Ice Polo Robolop Design -- posted image.

And a lath which functions as a glider for the mill.

Ice Ice Polo Robolop Design -- posted image.

This looks pretty smooth and easy, but when you look at the clock, hours pass by. But I donít care about the time.

Ice Ice Polo Robolop Design -- posted image.

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