Flush mounted tweeter for DSM

[AWD Terror]

The following is by DSMtalk.com Community Member talontsiawd (http://www.dsmtalk.com/forums/member.php?s=&action=getinfo&userid=1753)

<B>Flush mount tweeter for DSMs</B>

<img src="http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter-icon.jpg" align="left" border="0"> Build yourself a custom fitting mount for tweeters for your stereo in your DSM.
DSMtalk.com Member talontsiawd shows you how.
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<br> I was tired of having my tweeters on my components just sticking out on my sail panel and after seeing UVaJester's flush mount tweeters i decided to do it my self. Here is a little run down on how to do it. First go to your local hardware store and find a piece of PVC pipe that fits or is close to fitting you tweeter. I found that since mine tappered, there wasn't a size that fit perfect but a dremal tool solved that.

Tools:
Dremel
Drill
Hole saw for drill
Foam Paint Brushes
Belt sander
Saw (Coping Saw works great)
Pipe cutter

Materials:
Fiberglass Resin and mat
PVC pipe
Expoxy or JB weld
Body Filler
Paint

Total time:
5-10 hours depending on skill level (including drying time for resin and body filler-2-3 hours).

The first step is to cut the PVC pipe to the desired angle so the tweeters point at you. Cut with a saw and then use a belt sander to make sure the the surface is perfect. Cut enough so that you can use both sides so they have identical angles. Then cut the length to size with a pipe cutter.
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter1.jpg

Next, expoxy or JB weld the PVC pipe at the desired angle to the sail panel
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter2.jpg

Next use a hole saw on your drill to cut a hold in your sail panel. Use a dremel to clean up your cut to match the PVC pipe exactly.
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter3.jpg

Test fit your tweeter and use a dremel to trim off anywhere that interfers with the tweeter placement
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter4.jpg

Now, steal you moms, girlfriends, or you own pantyhose (if you're a girl or if you're a man with a weird fetish) and stretch it over your panel. Use some tape to hold it in place and make sure you have no wrickles. Be careful here because this will create the 3D shape of you panel.
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter5.jpg

Coat it with some fiberglass resin to get your basic shape.
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter6.jpg

Wait for the resin to dry and then reinforce the panel with fiberglass mat. Try to make it as even as possible but remember you can always sand it down if you have rough spots. I used two layers which was strong enough.
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter7.jpg

Sand off any excess fiberglass starting with a dremel and some hand sanding.
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter8.jpg

Now that you have the panel in its basic shape, use some body filler to clean up any imperfections. If you were careful, you don't need to use that much. Sorry, but I forgot to take a picture of this step.

Sand the body filler to your liking and paint it the desired color. I found Semi Gloss Black matched very well to the stock color. Put your tweeter in when the paint drys. Mine fit in by pressing them in but you may need to secure it if your hole is too big. I suggest a hot glue gun since you can peel it off if you need to.

Now you have a custom flush mounted tweeter that looks like it was OEM!
http://www.dsmtalk.com/forums/images/articles/tweeter/tweeter9.jpg

I will take some day time pics later. I found this project very easy and I have very limited experience with fiberglass. This is something anyone can do if they take their time. If you haven't worked with fiberglass at all, I suggest you make something simple (like cover a piece of wood) to practice. It takes very little skill but you need to take your time and sand it to the shape you desire. I did one at a time but if you do both, it will only add a bit more time than doing one.

Questions or comments? Please discuss this article here (http://www.dsmtalk.com/forums/showthread.php?s=&threadid=117732).