First up, shout out to @Devils_smile for all his assistance, both in purchase, advice and procurement. The stuff was either purchased from him or through him. My experience with him has been flawless since I dealt with him first Summer last year. He is extremely helpful not only in what he has/ had but also going out of his way to get stuff from other sources most notability Sound Valley. I thoroughly recommend him for assistance as well as purchases. Speaking of, thanks also goes to sound valley for hardly ever picking up my phone; J/K. I have bought tons of stuff from him, few directly since its impossible to get hold of him.
Anyways the build is an evolution of what started last July. I replaced the stock Suzuki Swift HU with nakamichi 5510 (@devils_smile), and the speakers with JBL 624 (front, sound valley) and Nakamichi (forget which ones, but from @devils_smile in the rear).
The HU went through several changes (Pioneer, Onkyo and finally Dudu 7), while the speakers remained the same... unitl now.
Why tone deaf? Because i think Dudus and Pioneers sound the same. This is how this journey of upgrade started off.
The New Hardware
1. Recoil RX 65 2 way co-axials front and rear. (From @devils_smile). BNIB.
https://recoilaudio.com/product/rx65-echo-pro-series-speaker-system2-way-coaxial-speaker/
Recoil DI800.4 Amp (From @devils_smile; Sound Valley). BNIB
https://recoilaudio.com/product/di800-4-full-range-class-d-4-channel-car-audio-amplifier-1500-watts-2-4-ohm-stable-mosfet-power-supply-bridgeable/
Recoil MALOC 4 (Adustable Line Output Converter ((From @devils_smile; Sound Valley). BNIB
https://recoilaudio.com/product/maloc4-4-channel-adjustable-micro-line-output-converter-with-10v-output-and-remote-turn-on-trigger/
Recoil Speaker Wiring Kit PCK 84 (From @devils_smile; Sound Valley). BNIB x2.
https://recoilaudio.com/product/pck84-true-8-gauge-99-99-oxygen-free-copper-complete-4-channel-amplifier-wiring-kits/
Tools of the trade
I used the following for installation, set up and testing. I have had this stuff for quiet some time now mostly procured from ali express, daraz, amazon, speedy (Australia) or locally from sound valley Rawalpindi
Antivibration butly-aluminium sheets (Sound Valley). For this build as support around speaker opening in car doors. Otherwise for as a sound barrier
Rollers (Ali Express). For applying the anti-vibration sheets
Dielectric grease & Vasline. Prevent rust build up on speaker mount U-clips, screws and speaker terminals. These can be bought from virtually anywhere
Spade connectors. While the PCK84 includes connectors the RX65 featue a large +ive and a smaller -ive terminal. the kit only has large spade connectors, the connector kit has connectors of all sizes (Daraz)
DMM & Scope. DMM is essential to check continuity, resistances. Can also be used to set amp gain. Scope is optional.
Speaker Rings (Sound valley). Rigid support. what else?
CCF sheets (ali express/ daraz). These are used generally for NVH reduction. Here i used it as a 'gas-kit' around speaker rings to create as airtight a seal as possible
Installation Process
1. The amp is mounted on MDF under the passenger seat. The OFC speakers wires run from the amp to the speakers. This was the toughest part for me. The stupid grommets/ ducts that run from pillars to doors are a pain to pass speaker wire through even with a wire snake. Undoing both ends and the clips that hold the conduit on the door makes the job easier, but it is still a chore.
The power to amp runs from the battery (recoil wiring kit fuse near the battery; i'll post pictures of this a little later) via the grommet on the passenger size, under the center console (door side used for audio cables to the amp. Ground is to the center console mount.
Initially the idea was to take high signal input from the amplified outputs of the HU to the LOC , and adjust the signal for the amp. I did some scope testing (other thread), the Dudu 7 can output >4V on the pre-outs provided speaker power is set to max under sound setting. So for now, Input is via pre-outs negating use of LOC. If I run into issues, installing the LOC is pretty simple. (I have not set up the rig just yet).
The Butyl-Al sheet is cut in a 1 inch ring to fit around the speaker frame in the doors. The U-clips are white enamel painted to prevent rusting and covered in dielectric and vaseline. The speaker ring's front and back are covered in a thin strip of adhesive CCF to create a seal. I dremelled bits off the speaker ring where it fixes to the door frame as the screw length of the U-clips either those that I had, or those that come with the speakers isnt enough to pass through the Butyl-Al sheet, CCF and speaker ring. Later I covered the cut-out with high-density CCF (see pictures below). Speakers are fixed to the ring by standard 1in screws. I used as many as possible.
To Do
Test Everything out -I am waiting for some other stuff, not audio related to arrive. Since the car is undone, no better time to fit other stuff that was in the pipeline anyways
Cable Management. I have some enclosures to hide all the cables around the amp. I deliberately avoided cutting the excess speaker wire for now. I will also isolate power incoming to the amp from the speaker wiring.
A bit more sound insulation on the door panels. I read up on ceramic wool as a sound insulator. It acts like OCF and is water proof. I ordered some from daraz waiting to try it out.
I will update the thread as I do stuff and get time.
Pictures
Butly-Al Sheet Rings & U-Clips
https://imgur.com/Qbrpd89
Speaker Rings. Notice dual strips of CCF foam as gas-kit and dremelled out areas for U-Clip Screws
https://imgur.com/HQwMuc9
Speaker in place. The wires you see were for the old speakers. They arent used any more
https://imgur.com/ifKgoxa
CCF filling the dremlled out areas & covered with Butlyl-Al bits
https://imgur.com/k4q7BQY
https://imgur.com/ifKgoxa
The Amp. The mess of wires and mingling of power and speaker wires will be managed
https://imgur.com/vtlMo3M
Thank you
