2nd Gen Sail Panel Tweeter Pod Build

I thought I’d track the progression of this build and post it here incase it helps anyone else. This was my first time using bondoglass and bondo filler, but I feel everything went well.

First, I started with the plain panel and used a utility knife to cut out the plastic structure. Then I drilled out and filed out the hole big enough to angle the MDF speaker ring properly.




Here, you can see the laser mounted on a scrap wood puck. This is hot glued to the ring so I can ensure the aiming is correct. I opted for the middle edge of the headrest front.



After gluing some dobs down to keep the angle in place, I used some matchsticks to act as structure to keep everything solid while applying the fillers. This also gives the bondoglass something to hold on to.

After applying bondo glass and sanding.

I applied a lot of filler so I didn’t have to do this step twice.

Make sure you wear a respirator while sanding.


I used suede to wrap the pod as it is more forgiving on imperfections than paint is. Because of the shape, I had to cut a relief slit to get rid of bunched up material.



Here is the final result! I am very happy with the result and I learned a lot. I still have to do the driver’s side so if I learn anything new or helpful tips, I’ll post them in the replies below.






I would love to see some builds from other people so if you have em, post them down below. God Bless!

 

Great job once again! The laser pointer trick is brilliant—I'll definitely be using that idea in future projects.

 

$6 at the pet store was so worth it!

 

Clean and functional, might have to steal the laser pointer idea. I also like the suede finish a lot. Great job!

 

Very clean!!! How long would you estimate to do this one

 

Thanks guys!

Cutout, aiming, and structure gluing took 1hr. Bondoglass sanding took less than 30 minutes and bondofiller took about 45 minutes of sanding. These times exclude time to apply and let dry over night. The suede with self adhesive backing took 30 minutes to get right, but I’ll probably be able to do it faster on the driver’s side one

 

Today I finished up the driver’s side pod. I manipulated and cut the relief seam a bit differently on this one and I feel it’s a lot cleaner. I may redo the passenger one down the road, but for now it will be fine. I’m really happy how these turned out. Now I have to wait for the rest of the system components to get wrapped up before I can hear these things in action.


Passenger

Driver

 

If I didnt have a boost gauge in one of my sail pods. I would totally ask you to make another pair!!!!

That's amazing work for under 3hrs per side. Super impressed.

 

Thanks man! I’m kinda tempted to do some 3.5 mid range speaker pods in the A-pillar down the road.