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Spare Wheel Sub Box Mini Guide

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  • Spare Wheel Sub Box Mini Guide

    As per previous requests here is a mini guide to building a Spare Wheel Well Sub Box for the S2 Coupe.

    Before I start I should point out that VAGsport (Sienna) originally built the box and subsequently sold it to me. I do not have detailed measurements for it, but hopefully the will be enough information for some of you to be inspired to have a go and build your own. Also, as you can see from the photo's it was a prototype and had some changes made along the way.

    Okay here goes.

    This sub box has been built in such a way that it fits very snuggly in the spare wheel well and does not have to be strapped or bolted in place. I also designed the Amp rack so that this also held the sub box in place. It should be noted however that is may be possible to use the spare wheel mounting fixing to secure the sub box by removing the speaker fitting the box and screwing it to the existing Audi spare well fixing with a bolt and refitting the speaker.

    Basically the Sub box is constructed of three basic elements.

    1.) A front face plate. I would suggest using 15mm or 18mm MDF for this.

    2.) A triangular sub box. Again 15mm or 18mm MDF would be suitable.

    2.) A curved plywood decorative panel. I think this was made from 6mm plywood.

    The result you are aiming for is this:
    Attached Files
    The Perfectionist
    sigpic
    Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

  • #2
    1.) The front face plate has the following rough dimensions:

    Width = 520mm
    Height = 575mm

    I would recommend making a cardboard template until you are completely happy with the result. I should look something like this:
    Attached Files
    The Perfectionist
    sigpic
    Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

    Comment


    • #3
      2.) The Triangular box. This has the following dimensions and will ultimately depend on the speaker type that you are using and whether or not the box you are designing will be ported or not. I would strongly suggest you stick to the speaker manufacturers recommendations on box size!

      With reference to the below photo, my box is approximately:

      Triangular end:

      Hypotenuse = 450mm
      Long side = 380mm
      short side = 280mm
      vertical height at 90 degrees to hyp = 230mm

      Width across box between to triangular end plates = 355mm
      Attached Files
      The Perfectionist
      sigpic
      Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

      Comment


      • #4
        3.) Plywood decorative panel:

        This is probably the hardest part. Again the best way would be to make a cardboard template before you cut any material. The width of this part on my box is 247mm and is made from 6mm Plywood. If I remember my school wood working class correctly I think the proceedure to make curved panels is to soak the wood apply it the curved edge of your front plate and allow to dry in the curved position. My box also has some small support blocks attachd to the back of the face plate under this plywood top cover.
        Attached Files
        The Perfectionist
        sigpic
        Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

        Comment


        • #5
          Once the box has been finished the whole lot was carpetted using some standard black sub box carpet bought from my local motor factor. This was glued in place with some Automotive multi purpose adhesive bought in an aerosol.
          Attached Files
          The Perfectionist
          sigpic
          Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

          Comment


          • #6
            Finished Boot:
            Attached Files
            The Perfectionist
            sigpic
            Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

            Comment


            • #7
              F*cking A mate!!!!

              Top write up and i will give me a good base to start a reproduction.

              Thanks!

              Comment


              • #8
                No worries.

                Managed that one and the false floor article in about 1.5 hours!

                Good luck.

                Cheers,

                Steve
                The Perfectionist
                sigpic
                Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

                Comment


                • #9
                  No worries.

                  Managed that one and the false floor article in about 1.5 hours!

                  Good luck.

                  Cheers,

                  Steve
                  The Perfectionist
                  sigpic
                  Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

                  Comment


                  • #10
                    Very tidy when finished, great work.
                    acidtrax

                    Comment


                    • #11
                      Cheers! I always promised myself a proper Stereo install when I got my S2!

                      The Perfectionist
                      sigpic
                      Audi Class Concours winner Stoner Park 2014, ADI Concours D'Elegance Class Winner 2008, Runner up 2014. Winner, S2Forum Show'n'Shine Billing 2006 & 2008.

                      Comment


                      • #12
                        An excellent description this is. Good work. Thank you.
                        Gabor

                        96 ABY coupe full except sunroof. With Porsche big red brakes, remapped ECU, xenon lights, RS2 MAF

                        Comment


                        • #13
                          Build Document

                          I have put both write up's into a document. If you want a copy PM me, i'll try and host it on my website and put the link up as it's nearly a 1 meg file,

                          Sorry Mac users i haven't got a pdf converter at present, i'll dig one out.

                          Comment


                          • #14
                            excellent write up, Thats a project for this year im fed up with claires corsa having a better stereo than the S2. whats your site Jamo?

                            Greg
                            Greg

                            S2Forum.com Administrator & Webmaster

                            '93 Coupe with a few tweeks

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                            • #15
                              If you want the document click on the link: http://www.jamo480t.pwp.blueyonder.c..._Box_Guide.doc

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