проблема бензобака \ как ломать стереотипы (ЗЯ вместо полки) — Toyota Mark II, 2.5 л., 2000 года на DRIVE2

It all started back in 2003, when a sedan car, produced by Toyota, produced in 1993 - Toyota Mark 2 JZX90 with tourer s configuration, fell into my hands. Until that time, of course, like any teenager, he was fond of music and everything that was associated with it. He even worked a little as a DJ in a nightclub. But this is another part of my life. So, the car is in the hands, there is a bullet in the head, and the accessories are in the store. Further, it would be a boring description of installing radio tape recorders, acoustics and ready-made subwoofers in the trunk. And it seemed there was happiness, the music was playing, the sound was pleasing and everything was fine, but even then I began to notice the "delay" of low frequencies and "dull bass". Further, due to the change of place of residence, the car was sold and the car audio mania was temporarily suspended.
In parallel with my new life, I periodically studied all sorts of musical literature, forums, watched reports on the installation of Sabov-stealth, freeware speakers, etc. But the thought of the problem of the "gas tank" did not leave me even in the absence of a personal car (I helped my friends install boxes in the trunks of different cars and constantly asked myself "why was the gas tank installed in the markoobraznye like this ?!"
And at the very beginning of 2009, a new dream car was purchased. I will not write a review of the purchase and "running-in", after all, I must finally write about the car audio. So, Toyota Mark 2 JZX100 tourer s 2000, white, restyled interior, in general a dream. Immediately surprised by the standard soundproofing. In recent years, I went almost only to the Russian car industry (I lived in the north-western region) and the contrast was, of course, on the face.
The Pioneer DEH-P7000UB head unit was purchased almost immediately. Why this one? First of all, the USB port, the preamplifier outputs of the front / rear / sub and well, the habit of the pioneer interface. I put it, set it up, turned it on and drove for a month or two, I didn’t take a steam bath, the sound was fine. The acoustics are standard, tuned up as far as I could, so that the doors do not "sing", but it seems like the low frequencies were heard. To be honest, I had no intention of installing sound in this car. Enough time has passed since the past, youthful hobbies to forget about them and think about Annette's bright future! Somewhere an article flashed, somewhere an advertisement, somewhere friends with their advice, whether they are not okay. As a result, I stumble upon an online report on the construction of a box of a complex shape for two 10k speakers. tourerv.ru/forum/viewtopic.php?f=16&t=38104... Guys, I confess honestly, such an idea flashed in my already infected brain, but this article served as a kind of kick to action. Reading the report and pondering my further actions, I decided that I should do it, for the sake of my autosound mania.
1. Planning. Budget.
I disassembled the trunk, removed the trim, the raised floor, pulled out the spare wheel and at the same time cleaned the niche of the latter. By the way there is a lot of dirt! Dust, small stones and everything to a heap. Then I examined the future scope of work, made measurements, poked my finger into the gas tank and said to myself "not a step back." It was not scary. It was interesting. An unknown future lies ahead, so to speak. On the same evening, at home, a rough drawing of the future box was drawn in three planes. The required amount of material was calculated with a margin of a couple of centimeters (I remind you that neither I nor the guys from the review had an exact drawing, everything was done with a jigsaw - it doesn't fit - we saw it!). Estimated information on the presence of glue (I used SuperPVA, a bottle of 300 ml, the price is about 150 rubles), screws (it took about 250 pieces, 3.30 rubles each) - with some kind of tricky coating, preventing twisting (I came across this after the first fitting assembly, swearing for a long time, it was daunting to unscrew it with an ordinary screwdriver), well, and I'll write about it below in detail. And most importantly, the main thing that I still did not even have in my plans was a head! Rather, two 10 inch speakers for working in a closed box of 25-35 liters. For three whole days :) I invigorated the world wide web in search. Hummer, hi-phonics, even kicker - but I wanted something cheaper, prettier, softer (let's omit consideration of performance characteristics of speaker models and equipment in general, we will leave it to magazines, shops, etc.). Found it in stock. But I live in one of the most remote regional center - the city of Yuzhno-Sakhalinsk (for those who do not know, this is an island. The arrival time of any cargo can vary from 3 to 45 days. Airplane - fast but expensive (from 3 to 10 days), train - cheap but long (25-45 days)), I really didn't want to wait and overpay for my unplanned needs. It was decided to leave the order for later, maybe something in the city could turn up. The budget for the speakers is 4-4.5 thousand rubles. I didn't want to spend more corny, otherwise it was possible to take a ready-made factory sub and make life happy. But we're not just mortals.
2. Purchase of raw materials
To match my hobby, there was a fire in our office on March 20. There would be no happiness ... In general, I saw this for the first time in my life. You sit in your office, work in your chair, go home, come in the morning, and there is not that there are chairs, there is no lime on the walls ... a slab with cracks the size of a finger ... or rather a fire of the 4th category. Okay, to hell with him, our rush, the floor was laid with 1.4 mm plywood, on top there is something else and linoleum as a result. Tears welling up when I saw how many scraps they had thrown out stupidly from the 4th floor. From such acoustics build and you do it! The foreman turned out to be a world dude, after talking for 5 minutes he realized what I needed (for the prostate explanation, I voiced that I needed a bedside table at home, and the only material in the world from which I can assemble it 1.4 mm plywood), and said that it would be easier for me to give him the dimensions of all planes, cut out and even immersed, I didn't ask for anything in return. Well, I gave him a chocolate bar for a good deed (0.5 quality). So the material is there, and even cut to my size. Glue and screws on the same day. Of the special tools, at that time I already had an electric jigsaw, an ordinary grinder, and an electric hand drill. Screwdrivers, etc. definitely! Not expecting such ease in the "acquisition" of the material, I decided to visit the local autosound "tycoon", the only competent installation studio on Sakhalin, Sergey, if you read it, thanks for the advice and all possible help. And here we are sitting with him, discussing the future, in his words “well, I don’t know, I don’t know,” the project and out of the corner of my eye I notice in the corner two boxes with the inscription MAGNAT AD-250 10 ”. As a result, I leave with a smile. Let's just say, I met the budget, but I didn't buy from him (there is no check), I just gave him money for business development, and he gave me a head in return. Production readiness 99%
3. Shelf.
We open the rear doors, remove the back seat, backrest. The rear shelf is in front of your eyes (some have an ionizer, and some already have embedded acoustics, because there, in the gland, there are as many as three holes for installing something that should play in the trunk volume). So, we pull together the shelf, take a jigsaw, and rushed ... The first thing I encountered was the softness of the shelf. The metal is very soft, it bends almost manually (I'm not Hercules), thereby preventing normal sawing with a jigsaw, the metal plays from vibration, and the jigsaw no longer goes into the far corner because of its height. I change the tool to scissors for metal, it turns out to work with them even more effectively than with a jigsaw, although by the end of the "cutting" fingers begin to hurt. I cut only from above (from the passenger compartment), in pieces, they fell into the trunk, respectively. To make it clear what size to make a hole, we sit down facing the rear window and look down at your entire shelf, in front of the seam, see? It makes no sense to cut the seam, you will go nuts to wave the scissors, the mode is either before it, or after, in short, next to it. Behind (or behind :)) there is the same seam, but the difficulty is in the inclination of the glass, you have to cut it already at an incline, thereby sometimes bumping into the seam itself. For a long time, after sweating in an unusual position, and having lost sight of a robotic Japanese assembly of the highest quality in the world, I cut a hole.

4. Nuances
- First. I have a rear wiper installed. When installing the sub, it had to be eliminated. The reason is the low location of the motor, it seems to interfere with the further location of the sub. We shoot. Unfortunately, the hole in the glass remains. We close it than necessary. I used my own rings, from the wiper itself and a bolt with a rubber round washer, a nut from the inside, tightly tightened, water does not enter.
- Second. Traction. Yes, the trunk will now temporarily not lift up by itself. We'll have to remove the transverse rods, it is not difficult, but for this I climbed headlong into the trunk, and be careful, I can shoot the rods, and not weakly.
- Salad. The light bulb from the "trunk ceiling" will also have to be removed. Then the truth is we will return it, but already on the raised shelf covering the sub's case and other amplifiers-capacitors. Those. all wires running along the "trunk ceiling" must be removed. All this will interfere with the installation of the box. To understand this, remove your own raised shelf, dive headfirst into the trunk and look up.
- Compote. The most important thing is to leave a niche from the spare wheel capable of functioning. I did it. The box does not reach the fixed spare wheel by about 8 cm, thereby leaving room for the original cardboard and the raised floor. With the box installed, I, just like any owner of a brand-like box, take out everything one by one, there are no obstacles to pulling out the spare wheel, jack and other things. The most important thing that remains to be done is to find shock absorbers that will lift or at least keep the trunk open. Who tried the weight of the trunk lid ?! Stop a hundred kilograms!
5. Making a box. At school, in labor class, my favorite was to work with wood. If this is also not difficult for you, then you can skip this paragraph.

The box consists of 7 longitudinal and three (!) Transverse parts.
1 - the side facing the street.
2 - look at the floor.
3 - contacts with the rear plane of the gas tank.
4 - this side of the box lies on the gas tank.
5 - connects the trunk / salon with the wall
6 - front side, the place where the speakers are installed.
7 - the dull side looking up, it is this part that needs to be done along the profile 1-2 cm lower due to the peculiarities of the body.
In general, there is nothing complicated here. A jigsaw in his right hand, a disassembled trunk in his left. According to measurements, we cut out one cross with a margin of a couple of cm and go to measure, adjust. Slightly rests, we cut. In order to understand what form to make, you need to understand how the box will be installed in its place, how it will fit in the trunk. The very understanding of the process will come during its initial execution (mosk and hands must be in place). After the crossbar in one place falls into place like a native, do not rush to cut copies, move it along the entire length of the gas tank, it will in any case rest against the fuel pump flap. Oops, exactly. We'll have to beat the hatch. This is not difficult, mentally turn the box over and make a recess in the 4th plane (as it looks like in Figure 3, marked with blue stripes).

Well, then we do our best so that we get two closed boxes of 25-35 liters each. Displacement depends on how to build the box, you can make it narrower, you can shorter, etc. I still haven't measured mine. Judging by the external parameters, about 30 liters per speaker. Then we adjust it all, assemble it, glue it, scroll it, put it on ... oops, it doesn't fit, we take it out, look, disassemble, saw it, put it back together, put it on ... yes, that’s what ... I spent my working week at this pace from 19:00 to 23:00 (i.e. you can add the time, work on the weekend is just something to build a box). As a result, the box is ready, glued, stretched, dried and ready for installation.

6. Installation.
Pay attention to the fact that the box is right next to the “ceiling”, which is what I meant when I wrote about the need to pick out the wiper and the light bulb. The higher the box is, the higher it will be inside the cabin, like this:

Yes, of course, by giving a slightly different shape, you can raise the front side of the box even higher, but unfortunately, due to the peculiarities of the body structure, it will be unrealistic to put the box in place. That is why side 7 in the profile should be omitted, as it were.
Now let me tell you a little secret. How does the box stay on the gas tank and doesn't fall into the trunk? It's simple. Side 5 directly contacts the trunk / interior wall, here it is, in Figure 6. At this point, I was not afraid of anything and decided to save time and nerves, which is called "head-on" screwed the box to this wall. It is now more than entrenched. In the longitudinal plane, it is bolted to the wall (the only rigid connection with the body), in the transverse plane, it simply lies on the gas tank. The weight of the box is about 15-17 kg without speakers. Not a little, I agree, but how much does a subwoofer weigh, and most importantly, what power should it be so that it can give the same juicy, deep bass and, most importantly, in the cabin (!) ?! That only I have not tried in my trunk and a 2-kilowatt Audiobah and a poltorashka Kicker. Yes, it did, but it all played somewhere on the street, in the yard, but not in the salon. This is the "gas tank problem". No, unless, of course, you are pure kankrete guys, and you get kicked in when they swear at you at three in the morning from the 9th floor for listening to music loudly, because all the sound goes out into the street, then close this page now, this is not for you.

7. Connection, configuration, testing.
Left a little. I put my heads upside down to create an effect. I did this not because the speaker does not rise in depth (however, this is also worth paying special attention to when choosing). I just wanted it so, so cute. As for the overtones from the ventilation of the magnet (inveterate sound people will understand me), there is, but only in peaks (the basket travel is about 1.5 cm, it will pump air, and it did not work out to collect completely sealed box), but I rarely bring it to peaks, it presses so not weak. Fixed the speakers, too, no frills. In those stores I bought 12 roofing felts of nuts, roofing washers with an internal thread and sharp clamps along the outer radius (used when working with wood, furniture), and 12 bolts. For everything about everything, about 100 rubles. Lack of experience with wood - holes were not drilled at an angle of 90 degrees, did not check on the spot, I stuck the box in, but couldn't put my head down. It is trite, but once again proves that everything needs to be checked twice. At the end, I already wanted to finish as soon as possible and go with the music.
I already had an amplifier, so I did not add it to the budget and will not. He is already changing the third car. Cadence ZRS-2002. Two channels of 400 into 4 ohms. More than. I screwed it trivially onto the back of the box (ahhh, so that's why these bars are screwed ...), next to it I screwed a capacitor (noname, we will consider the production of mistery). The wiring has already been carried out, acoustic wires of a large cross-section were purchased (by the way, also noname). Connection with protruding tongue within 15 minutes and you're done ...
So, the main thing is not to get excited, the main thing is to keep yourself in control and do everything according to the instructions ... ignition ... radio tape recorder ... settings ... sub ... turn on ... cut off to 60 Hz ... no, to 125 Hz, listen to overtones. I rejoice in the trunk, adjust the wuxia. Gain to 0le, filter to Low Pass, move to max (150 Hz is written), all sorts of +8 dB esessno 0. Raise Gain. Wow, it works. -Pause- deliberately did not turn on the box in the removed state, I wanted to surprise myself. I run back to the salon, do it quieter, back to the trunk, raise the Gain. I close the trunk, pinching my fingers (I forgot that the rods were removed). All the rules, fingers are intact. I close the doors, windows, turn on my own cutter on the radio tape recorder along the bottom to the front and rear. I make it louder and listen to every sound (I tuned it out of habit on the Audio-Doctor Autosound disc). Guys, these moments are worth living for. Describe what

At the moment I am working on "crickets", slowly making a false shelf. By the way, this should be discussed separately based on the abundance of material in the city. It could be made of fiberglass, or you can throw plywood. Everyone will choose for himself. So far, I glued it with a vibrating m1, glued it on top with spleen, and on top I will lay it with an ordinary black carpet (I remind you that the interior is dark). In the trunk, as you can see the removal of the box together with the amplifier, the trunk practically does not eat up, when compared with a standard raised shelf, but if we compare it with factory boxes, I am already generally silent. In general, the trunk remains fully functional, no matter how small or large it is called in the brand. Above the box and the weasel (of course, I plan a 4-channel and the replacement of acoustics), a shalesh shelf will be made, enveloping the box and not interfering with the trunk closing / opening mechanism. It is quite possible that I will make backlit plexiglass windows there, or even with a radiator outside. In any case, the project is 80% completed, works in full force and gives real pleasure to the owner and the views of misunderstanding among others.
Thank you for reading to the end, I have a photo at the end of the project.