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JS Designs/Sony Xplod '05 Honda Civic SI Custom Door Panels - How-To

JS Designs Sony Xplod 05 Honda Civic SI Exhaust Chambers Molded
The exhaust chambers were... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Exhaust Chambers Molded
The exhaust chambers were molded to the body of the car with body filler.
JS Designs Sony Xplod 05 Honda Civic SI CNC Exhaust Guards
The CNC exhaust guards were... 
   
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JS Designs Sony Xplod 05 Honda Civic SI CNC Exhaust Guards
The CNC exhaust guards were bolted to the mold and the exhausts were test-fit.
JS Designs Sony Xplod 05 Honda Civic SI Door Panel Test Fit
The concept car and the door... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Door Panel Test Fit
The concept car and the door panel were installed on the car for a test-fit.
JS Designs Sony Xplod 05 Honda Civic SI MDF Base
Quarter-inch MDF was cut to... 
   
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JS Designs Sony Xplod 05 Honda Civic SI MDF Base
Quarter-inch MDF was cut to form the base for the tweeter rail.
JS Designs Sony Xplod 05 Honda Civic SI Steel Pipe
Half-inch steel pipe was flattened... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Steel Pipe
Half-inch steel pipe was flattened on the edges and bent to the desired shape.
JS Designs Sony Xplod 05 Honda Civic SI Rail Glued
The rail was glued to the... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Rail Glued
The rail was glued to the top of the door panel and checked for clearance in the door opening.
JS Designs Sony Xplod 05 Honda Civic SI Tweeter Mounts
The tweeter mounts were glued... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Tweeter Mounts
The tweeter mounts were glued to the rail in proper placement on both sides.
JS Designs Sony Xplod 05 Honda Civic SI Speaker Wire Tweeter Rail
The speaker wire was precisely... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Speaker Wire Tweeter Rail
The speaker wire was precisely fed into the tweeter rail.
JS Designs Sony Xplod 05 Honda Civic SI Tweeter Rail Test Fit
The tweeter rail was placed... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Tweeter Rail Test Fit
The tweeter rail was placed onto the upper door panel for a test-fit.
JS Designs Sony Xplod 05 Honda Civic SI Glazing Compound
Glazing compound was applied... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Glazing Compound
Glazing compound was applied to the entire door panel to fill-in scratches and surface imperfections.
JS Designs Sony Xplod 05 Honda Civic SI Gauge Pods
The tweeter mounts were molded... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Gauge Pods
The tweeter mounts were molded into the rail to create gauge-like pods.
JS Designs Sony Xplod 05 Honda Civic SI Final Mock Up
Here's a final mock-up of... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Final Mock Up
Here's a final mock-up of the door panel.
JS Designs Sony Xplod 05 Honda Civic SI ABS Oval Cut
A 1/4-inch ABS oval was cut... 
   
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JS Designs Sony Xplod 05 Honda Civic SI ABS Oval Cut
A 1/4-inch ABS oval was cut and flush-routed to become the base of the tweeter rail.
JS Designs Sony Xplod 05 Honda Civic SI MDF Template
A 1/4-inch MDF template was... 
   
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JS Designs Sony Xplod 05 Honda Civic SI MDF Template
A 1/4-inch MDF template was cut and molded into the door panel, and transferred to acrylic so it could be the door-release button.
JS Designs Sony Xplod 05 Honda Civic SI Fiberglass Bodies
Both fiberglass concept car... 
   
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JS Designs Sony Xplod 05 Honda Civic SI Fiberglass Bodies
Both fiberglass concept car bodies were aligned to ensure absolute symmetry.

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