Results 1 to 7 of 7

Thread: 2004 Saturn Ion, Audio install, carputer later.

  1. #1
    Wants to make it harder monkeyracer's Avatar
    Join Date
    May 2007
    Location
    Lakehood, CO
    Posts
    1,463

    2004 Saturn Ion, Audio install, carputer later.

    My brother wants me to help him install subs in his 2004 Saturn Ion. He doesn't have plans in the very near future to put a 'puter in, but I think once mine is done, he'll want one. This post is to document the process we took and the problems we've run across during the install. This is more specifically directed at the fellow saturn owners, and to guide someone through the process in general. There are plenty of sub installs on this forum, but those with the Ion, here you go:

    Day 1 - Planning:

    Planning is one of the most important parts of doing any install. This is more simple compared to a 'puter, but still needs to be planned out.

    1. Decide on components:
    -Amp - Sony XM-2200GTX 2CH "760w" (when lightning strikes) 190W x 2ch @2ohm each in reality.
    -Subs - 2 Pioneer Premier TS-W1207D4 1200W max, 300w RMS Dual 4 Ohm Voice Coil 12" Subwoofers.
    -Custom Built Box - More on this below. Each side is going to be pretty close to 1.25 Cu Ft which is what pioneer recommends for these subs.
    -Power - 8 AWG monster cable, 80 amp fuse/holder.
    -Audio Cables - Monster Cable 201XLN 2CH 5M Audio Interconnect with RCA connectors.

    2. Decide on placement of components:
    My brother wanted the subs to be in a simple box in the middle of the trunk against the back of the back seat. The amp will be mounted to the top of the box, with blue led cooling fans. To add to the security we are using various different screw heads, and one uncommon head. Most thieves will not have the bit or driver needed for the uncommon one, and won't be able to get it out. We also are going to rebuild the trunk floor to provide a stronger shelf for everything back there.
    We measured the trunk and put the dimensions into AutoCAD, and verified the volume before we put blade to wood, and to give us a better idea of the design. The subs work best in front of 1.25 Cu Ft of air space, we have 1.24 with the sub's displacement accounted for. That's close enough. (within 1%)

    Day 2 - Building, testing:

    3. Measure, measure, measure, then cut:
    After getting the supplies we needed based on our designs, we measured the width and depth of the trunk floor to cut the MDF to fit. Then we measured the available height after the new floor is in. We also measured the maximum width for the box, just to make sure the design we made yesterday would fit. The box we are making has two separate chambers to isolate the subs (we are wiring them in stereo, and subs should only share air space with other subs on the same channel.) Each chamber has a volume slightly greater than 1.25 cu ft to compensate for the displacement of the sub itself. The amp will be mounted to accommodate the LED fans. This is then covered in enclosure carpet that is pretty close to the carpet already in the trunk. Our local upholstery shop sells the carpet as "trunk liner" and is about $5/yd. (They are also a great place to get vinyl, leather, etc...)

    4. Install amp and subs, put in car:
    After test fitting a thousand times, we finally were able to put everything in for good. We screwed the box to the floor so it doesn't move around, and it's harder to steal. Then, we mounted and wired the amp, and screwed the subs into the holes. Amp tuning was already set from the previous install, but fine tuning can still be done with the seats folded down. There is a little space to the sides of the box, it will be used for storage for things like windshield washer fluid, jumper cables, etc.

    - My brother is very satisfied with this install, he said this about it:
    "Everything is professional, and clean. No wires left lying around, and the box looks like a pre-fab, except it's actually the perfect size for the sub. Everything is in it's place and fits perfectly. The trunk floor is really cool too, now it's stronger, and more functional. I love it all, especially the sound."
    2007 Chrysler PT Cruiser TE
    Car PC Progress:
    Planning.......[---------X-] 95%
    Parts...........[---------X-] 90%
    Fabrication...[---------X-] 90%
    RR Skin........[---------X-] 95%
    View my
    Worklog
    Road Runner Skins
    Website
    Favorite thread EVER!

  2. #2
    Wants to make it harder monkeyracer's Avatar
    Join Date
    May 2007
    Location
    Lakehood, CO
    Posts
    1,463
    pics:

    Set up work area.

    First Cut

    Cutting holes out with speed/spiral saw, using circle cutter. This made it so much easier to cut almost perfect circles.

    Assembling the box, attaching the adjacent panels to the face.

    Adding the side and center pieces.

    Adding the back, after sealing all interior edges with the silicon sealer. There's a screw every 3" or so on this box.

    Empty trunk, measuring for new trunk floor.

    Transfer measurements to the MDF.

    Floor installed, test fit with sub to find where to cut joint to still be able to get to spare tire.

    Joint cut, hinges installed, test fit again to make sure we cut it right, still able to access spare and battery easily.

    Starting to carpet box.

    What to do with this edge? well, wrap it like a present, cut down the center of overlap, remove excess. You can't even tell there's a seam unless you get right up close to it.

    Speaker terminal cup close-up, almost flush with carpet of box, makes install/uninstall so much easier.
    2007 Chrysler PT Cruiser TE
    Car PC Progress:
    Planning.......[---------X-] 95%
    Parts...........[---------X-] 90%
    Fabrication...[---------X-] 90%
    RR Skin........[---------X-] 95%
    View my
    Worklog
    Road Runner Skins
    Website
    Favorite thread EVER!

  3. #3
    Wants to make it harder monkeyracer's Avatar
    Join Date
    May 2007
    Location
    Lakehood, CO
    Posts
    1,463

    Wiring the amp up, in this shot, there is two power wires going to the amp, we had some extra that we used for testing everything, but as you can see in pictures below, we put the right cable in.

    Other side of wiring, Each wire is held in by a ring terminal rather than spades (fork terminals) so that the wires can not be pulled out.

    Amp on top of box, just barely fits, it's touching the cross bar here, which may help in cooling by transferring some of the heat to the metal of the car.

    But, we added fans anyways, this amp gets hot and is getting old, and temps have been getting high near here lately. The fan mounts will be carpetted soon, just eager to get everything in.

    Cleaned up wiring, notice the ground wire is silver instead of red. Also, we used banana jacks to plug into the speaker wire. This makes it easy to remove the subs if we ever need to.

    With subs installed, oh so nice.

    Close-Up

    Other views:






    -edit: this was my 200th post! woo hoo!
    2007 Chrysler PT Cruiser TE
    Car PC Progress:
    Planning.......[---------X-] 95%
    Parts...........[---------X-] 90%
    Fabrication...[---------X-] 90%
    RR Skin........[---------X-] 95%
    View my
    Worklog
    Road Runner Skins
    Website
    Favorite thread EVER!

  4. #4
    Wants to make it harder monkeyracer's Avatar
    Join Date
    May 2007
    Location
    Lakehood, CO
    Posts
    1,463
    The amp is still getting too hot and cutting out. But this is after an hour of full volume playing, on a warm day. We're going to add a larger, higher air-flow fan, and see if that helps.

    edit: the fans were both blowing air away from the amp, we turned one around and it blows air across the amp, and the second fan blows that air away from the amp. This helped, hasn't gone into heat protect since, but we will give it some time before we call it good.
    2007 Chrysler PT Cruiser TE
    Car PC Progress:
    Planning.......[---------X-] 95%
    Parts...........[---------X-] 90%
    Fabrication...[---------X-] 90%
    RR Skin........[---------X-] 95%
    View my
    Worklog
    Road Runner Skins
    Website
    Favorite thread EVER!

  5. #5
    Low Bitrate Super_dave's Avatar
    Join Date
    Sep 2006
    Posts
    107
    Nice simple box , how did you cal the air space for the subs

  6. #6
    Wants to make it harder monkeyracer's Avatar
    Join Date
    May 2007
    Location
    Lakehood, CO
    Posts
    1,463
    The short answer: Math.
    The long answer: I just based it on a previous sub that was pretty close to the same size that actually listed the volume of the sub itself. It's .21 give or take. To double check, I took the sub's cut out diameter (11), multiplied by the sub depth (6), and divided by two for a rough estimate. This came out to around .21 cubic feet. If it's off, it's only off by a small fraction, and will still be within range of the recommendation.

    I love simple boxes, they are easy and sound great. All those complex angled, and cornered and curvy fiberglass boxes look cool, and they take some good hard work, but I don't really hear a major difference in sound. To me, it's not really worth the extra work to get the same sound results. Unless I was entering the car into a show...
    2007 Chrysler PT Cruiser TE
    Car PC Progress:
    Planning.......[---------X-] 95%
    Parts...........[---------X-] 90%
    Fabrication...[---------X-] 90%
    RR Skin........[---------X-] 95%
    View my
    Worklog
    Road Runner Skins
    Website
    Favorite thread EVER!

  7. #7
    Wants to make it harder monkeyracer's Avatar
    Join Date
    May 2007
    Location
    Lakehood, CO
    Posts
    1,463
    One note to those looking at the pics:

    Yes I used a jig saw to cut the pieces out. I don't have a circular saw, and didn't feel the need to buy one. It would have made for straighter edges, but with a good jig, it came close enough. Any imperfections in the edges were sealed with the silicon, and/or sanded down flat.

    I recommend using a circular saw, since the edges will look better, it might also be quicker to build, but it shows you that you can make a good box with different tools.
    2007 Chrysler PT Cruiser TE
    Car PC Progress:
    Planning.......[---------X-] 95%
    Parts...........[---------X-] 90%
    Fabrication...[---------X-] 90%
    RR Skin........[---------X-] 95%
    View my
    Worklog
    Road Runner Skins
    Website
    Favorite thread EVER!

Similar Threads

  1. 2004 BMW 325Ci Sport carputer install completed (& PICS)
    By HALAWA in forum Show off your project
    Replies: 14
    Last Post: 02-05-2009, 05:41 AM
  2. Replies: 6
    Last Post: 03-18-2007, 11:51 AM
  3. Would like some input on Saturn install
    By redbaron_714 in forum General MP3Car Discussion
    Replies: 3
    Last Post: 03-01-2007, 05:18 PM
  4. WTB: Carputer install help in SLO, CA
    By arebelspy in forum Classified Archive
    Replies: 12
    Last Post: 10-15-2005, 10:55 PM
  5. Carputer in '04 Saturn Ion Coupe
    By idg101 in forum General MP3Car Discussion
    Replies: 4
    Last Post: 04-06-2005, 11:40 PM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •