Like Jason mentioned earlier, the first thing they did was to completely gut the truck. Once that was done, aluminum backed dampening mat was added to every surface, with two layers in some places. With everything damped, wires could be added. The entire Frontier is wired up with Rockford Fosgate Connecting Punch power and speaker cable and interconnects. With all of this groundwork laid, the truck went off to the painter, Rocky's Pure Kustom, for its outrageous red, black and silver paint. At the same time, the factory seats were being completely re-done with the red, black and silver theme, in leather. Even the headrests have a custom aluminum Rockford Fosgate logo molded into them.
According to Bryan, "The focal point for the Frontier's installation was the sub box. That's where I had my vision in the desert and so once all the groundwork was set, that's where we began first with the fabrication." He and Jason started by making a mockup of one side of the sub box, basically a front plate that would hold three subs. Using that for the basis of the sub box's curved shape, he started on the curve of the rings that come out from the enclosure. The result isn't quite circular but more like a combination of two elliptical curves. Overall, the design was beginning to shape in reality, not just in Bryan's head.
To simplify construction, Bryan decided on a component or modular technique. Starting with a large panel of wood that would make up the back of the entire box, they started to add pieces or modules. First were two sub boxes, each holding three RFP-3210 10-inch dual voice coil woofers. They're actually built of flat panels that are filled in with body filler to match the contour of the sides. Next comes the arches. There are four of these and they're all built basically the same. Each part has the same left and right side, further simplifying construction. From left to right are: MDF panel, aluminum panel, Plexiglas panel, neon, Plexiglas panel, aluminum panel and MDF panel. They're basically a neon sandwich. A perforated aluminum panel sits between the left and right sides hiding the neon and letting the edge of the Plexi glow. To match the wheel well arches' design, the sub box arches have notches with big Allen-head bolts in them.
The next trick in the box's design is something that nearly everyone, myself included, misses. The Rockford Fosgate 10-inch subs are in a vented enclosure and the gap between the two arches in the middle of the box make a slot-loaded vent. If you look really close, you'll see another wider band of perforated aluminum in between those two arches. It's not possible to put your hand through the arches either. That's because a piece of 1/2" Plexi fills both arcs to form the sides of the port.
Looking inside the box with the woofers out, you see it's a common airspace so all the woofers use the port. "Designing that part was really hard," says Bryan. "I put the woofer specs into TermLab and it told me I would need a little over eight cubic feet for the six subs. We had four people measure the internal volume of the box in there own way to make sure we were right. We didn't know for sure until it was done and we checked the resonance of the port. Then I put the measured port resonance into TermLab and basically worked it backwards. We hit the required box volume and port size to within 5%. Not easy considering the odd size of the box and port!"