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Old 08-29-2005, 03:16 AM
Berliner Bel Air's Avatar
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how to punch nice hole pattern in package tray?

Hi,

I try to keep my car looking as stock as possible (original non-functional radio is in the dash). I have 2 tweeters, 2 midrange speakers and a remote controlled deck and CD changer in the trunk, all totally hidden from view. All except for the two back speakers in the package tray. It bothers me that they are so visible. So I want to create a new package tray with a pattern of holes in the shape of two ovals, where the speakers' sound would pass through. This would be much more subtle (i.e. nearly invisible) than what I have now.

Problem is: How do I create a nice template for an even, good-looking hole pattern? Has anyone used a computer to generate something like this?

Thanks

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Old 08-29-2005, 11:58 AM
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Is it possible to do the layout on a piece of cardboard and get all your cuts right then use that as your template for the final product? I think it would be the easiest to do. I'm sure you could use a CAD program to generate a 2D view but then you would have to plot it out. If you have the software and plotter, go for it.
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Old 09-01-2005, 07:51 PM
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I have a couple of ideas. 1) Check with a local car stereo installer. They may have something to fix what you have.
2) Cover the existing package tray with speaker grill cloth. I've seen raised speaker grills covered with matching cloth. It helps reduce the visual impact of the speakers.

Alternatively, if you can give me the basic dimensions, I'll draw some hole patterns that you can print and use.
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Old 04-15-2007, 03:32 PM
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The speaker cloth was a good suggestion. Here's what I did and it really hid the speakers in the package tray perfectly:

1. Buy some furniture backing, that cheap stuff that is like cardboard but much stronger, like pressed sawdust. Use the old cardboard package tray as a pattern and cut it out (with appropriate speaker holes).

2. Remove the speakers and remount them from the bottom, inside the trunk pushing them upwards. You need someone to help with the fasteners from inside the car.

3. Cover the board with a layer of fleece. This is important so that the board will look very smooth when installed. It also softens the outline of the holes. Also, speaker cloth is delicate, it would probably rip or get damaged if you don't pad the board. Pull the cloth about 2 inches over the edge and glue on the bottom side with contact cement. Next cut the openings for the speakers, but leave about 1/2 inch of material overlapping the hole (the hole should be slightly smaller than the speaker cutout.

4. Take the matching coloured speaker cloth (getting this stuff by the yard is the hardest part, look for it on the net) and pull over the whole tray. Make sure you give it a bit of tension so it's taut over the speaker opening, and glue on the underside.

5. Install and enjoy great sound and original looks!

Last edited by DanTwoLakes; 04-17-2007 at 11:16 AM. Reason: Violation of guidelines. Please see: general board guidelines.
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Old 04-17-2007, 11:11 AM
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Sorry

Berliner Bel Air: On the bottom of your post it says that I edited your post, and the reason was "violation of guidelines". What I edited was the word "taut" which you had spelled "taught". I am a new moderator, and was practicing my editing skills. You did absolutely nothing wrong, and I apologize for my error.

By the way, your solution was very good. You could also put any porous fabric (not vinyl, ultraleather, or leather)over the fleece with the same results. You can also staple the speaker cloth or fabric to the back of the board instead of gluing it.

Dan

Last edited by DanTwoLakes; 04-17-2007 at 03:16 PM.
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Old 05-15-2007, 01:25 PM
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I've used peg-board to lay out evenly spaced holes. All the holes are exactly 1 inch apart. Dan
www.geocities.com/dantechfab
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