Now that we were done with the outside modifications it was now time to move onto the inside. For the first phase of the project, Jeff and Reuben assembled Toronto’s finest team of fabricators and installers to help out with this massive part of the project. This team was headed by master fabricator Frank Valenti. Working under Frank was Matt Gordash, Cameron Gunn, Mark McGrath Ryan Griffiths and Louis Azzopardi. Jeff and Reuben both sat down with Frank to discuss the massive plans to transform the interior of the explorer into the largest mobile ICE car in North America. One of the main reasons for even beginning all the changes was to get a motorized 42” plasma into the car. Originally we were just going to lift the old install that was in the car and put the plasma below it. That simple plan went out the window once we started having meetings and discussing the project. Frank brought 20 years of experience and ideas to the project. When it comes to creativity and pushing the envelope no one does it bigger / better then Frank. Often referred to by his nick name “crazy;” Frank “crazy” Valentie makes sure that each install that he does is jut that… crazy!
The first area we wanted to attack was the sub enclosure. Our goal for the project was to get 21 12” subs into the car. We are disappointed to say that this was the only goal we did not make. Another goal of ours was to keep it a 5 seater vehicle to maintain maximum practicality. Unfortunately this goal stood in the way of our 21 12’s goal. At the end of the day we were only able to fit 12 12” Kicker Comp C12 4 ohm subs into the car. The out shell of the box was constructed out of 2 solid pieces of ½ inch MDF to give us a total wall width of 1”. With 12 subs (in a sealed enclosure) and a lot of power we knew we needed a strong foundation to build from. The outer shell of the box was cut, shaved and moulded to the contours of the car that rested right behind the rear seats. Once the outer shell was securely mounted in the car it was time to setup the 12 rings. We created 12 outer rings out of ¾” MDF. We then wrapped each ring with 1 1/4” slotted MDF which gave us a pocket for us to later counter sink 12” neon tubes around each sub. Even getting 12 subs into the wall wasn’t easy. Frank worked his magic, strategically placing each ring into the sub wall enclosure. ¼ Inch dowels were used as temporary supports until we could fiberglass them permanently into the box. One by one the rings were set into place. Once all 12 rings were mounted we stretched fleece over the rings pulling and stretching until we had the shape we wanted. A layer of glass was applied to the fleece to harder the shape. Numerous layers of fiberglass were applied to the inside of the box to re-enforce it from cracking later on or leaking air. Several coats of bondo were applied to smooth out the surface and get it ready for paint. By the time we were finished the box was approximately .8 cubes / driver x 12 drivers = 9.6 cubic feet. A custom trim panel was made to go around the box. This trim panel follows the contour of the car. It was wrapped with a blue suede material. Each sub was then accented by a 12” Alpha Line PPA-012BL neon ring.
We wanted to create a rear overhead panel. This panel extends from the sub wall to the middle of the roof liner. It would end right behind the front seats. It looked like the perfect area to add more TV’s. We fabricated the panel to fit 4 7.2” Innovatek IN-7288 TV’s. It contours to the roof just perfect and fits in with the sub wall as if it was one piece.
TAIL GATE:
The next panel to design was the trunk area. The box took up most of the trunk so we didn’t have much room to work with. When you open up the rear tail gate we wanted this view to be spectacular. We started off by laying out the concept that would be used for the video and audio sources in the car. We cut ¾” ovals which were representative of the oval in the Ford logo. These ovals were used to frame in the xbox and playstation that were integrated into the video system. A 120Gb hard was attached to the xbox to store up to 40 games at anyone time. The oval was also used to frame in a 10 pack Kenwood KDV-C810 DvD changer. Later these ovals will be trimmed with frosted plexi and lit up with blue neon. All ovals were mounted to ¾” MDF stands and set in place. A ¾” frame was made and fixed to the back of the box to hold a 17” Samsung LT-P1745 TV that would sit front and center when the rear hatch was opened. Although space was limited we were able to squeeze in two Kicker Comp C8 4 Ohm 8” subs; one on either side of the rear trunk area. Custom ¾” MDF sealed enclosures were made to fit to the limited space that was available. To dress up the back panel and add some lighting effects, 10 GE plexi tubes were cut and added with 10 Blue LED engines. We created two half moon setups; one on each side of the 17” monitor. Each setup holds 5 GE tubes. Once all the trim, ovals and boxes were set in place we stretched fleece across the back. We massaged the fleece until we got the exact fluid roll that we were looking for. A layer of glass was applied to the fleece to harder the shape. Numerous layers of fiberglass were applied to the back side of the panel to re-enforce it from cracking later or changing shape. Several coats of bondo were applied to smooth out the surface and get it ready for paint. Jeff smiles as he affirms that this is one of his favorite panels in the car. Space was left below the panel and in the tire well which would later become the home for the 42” Plasma.
To aid with the spectacular view of the rear section we decided to customize the rear hatch that opens and the glass on the rear hatch which opens independent of the main hatch area. We wanted this car to attract attention from far away. To help us accomplish this goal we added 5 6” Innovatek IN-600A TV’s to the upper glass. When this piece is open it stands over 10ft high and attracts attention from hundreds of feet away. To create this panel we attached the 5 shrouds to the stock panel that was there from the factory. We stretched fleece over the panel to create the shape that we were looking for. Once we had this shape set we glassed over it until it hardened. It was then bondoed, sanded, primed and painted.
With all the boom going on in the car we knew we needed to get some speakers firing out of the car. We created a custom panel out of ¾” MDF that would sit on the rear hatch. This panel was moulded on to the factory Ford panel. To keep the build consistent, the build out uses the same oval shape that we used for the playstation, xbox and dvd changer on the trunk of the car. This panel holds 2 6” Innovatek IN-600A TV’s and 1 pair of Kicker KS 5.2” component speakers.
Even though the main goal was to add the 42" motorized plasma to the install we still wanted it to be hidden. We wanted the car almost have two separate installs. Once with the plasma screen up, and one with the screen down. We accomplished this goal by camouflaging the tray that slides out. We added 4 6” Innovatek IN-600A TV’s and a blue LED digital display (with changing messages) to the face of the plasma tray. When the tray is closed the rear panel looks like one piece. You would never know that there is a motorized tray below it that holds a 42" plasma screen. To create this panel we cut a piece of 3/4" MDF that was the exact size of the opening where the plasma screen comes out. We mounted two of the TV shrouds to each side of the digital display. Once we had set the TV's in place we used fleece to mould the shape that we wanted. It was essential that this shape matched the rear panel perfectly so that it looked like one continuous piece. The panel was then glassed, bondoed, sanded, primed and painted.
The main feature of the car and #1 reason for even doing this install was to get a motorized 42” plasma into the car. We didn’t want to just flush mount the screen somewhere… we wanted to make it much more interesting. Mr.Valenti truly knocked this one out of the ball park when he designed a motorized plasma tray that would slide out from under the install and then flip up. This was one of the most intricate parts of the install. We started off by purchasing the Prima PS-42D8V3 42” plasma. We called in master welder Joe Ferraro from Ferraro Fitness to help out with the framing and supports for the TV. Mr. Valenti built a sliding tray on 36” metal sliders that could hold the weight of the TV. The tray was anchored to the floor of the car to ensure it could the weight of the TV and the Tray. Once the welding of the metal frame was made we inserted it into the sliding tray. Moving the tray in and out wasn’t the hard part. We fabricated mounts and used a 36” linear actuator which could handle the distance and weight that we needed. Getting the tray to pop up was a bit trickier. Precise angles were calculated and brackets were made that would hold the 24” linear actuator. We then attached a 4 Channel wireless remote to these actuators so all movements could be done remotely away from the car. The sliding tray and metal frame were painted for cosmetic reasons.
On the rear hatch of the car Jeff has installed a unique product called hide-a-plate from I.C.E. Depot. Hide-a-plate is a product that goes over your license plate and makes it disappear at the flick of a switch. Jeff thought this would be a great product to add so that at shows he could black out his plate without taking it off the car. The secret of the transformation between clear and translucent is found in the Liquid Crystal Sheet within the laminated glass panel. The randomly aligned Liquid Crystal molecules are such that it disperses light. However, when voltage is applied, these same molecules arrange themselves in a specific direction in such a way as to permit parallel light to pass through
the glass.
Finding homes for the 3 amps was a huge challenge with this project. With so much equipment fitted into such a small place it was hard finding room. Who would of ever thought you could run out of room in an SUV! When we got to the amps it was quite clear that we would have to get creative. The large sub amp (Kicker KX 1500.1) was simply mounted below the plasma tray. The other two amps which were matching Kicker KX 650.4 were not going to go in as easy! Once of the only places left to put them was the rear windows. We thought of removing the rear tint and just having them show through the fixed glass… now what fun would that be. Frank came up with the idea to remove the rear windows from the car and motorize them so that they would lift up like wings. Although this seemed far fetched we ran with it. Each window was removed from the car. 3 Pieces of 1/4” slotted MDF was were cut to the exact shape of the window. These 3 pieces were adhered to the window with black urethane and used so we could mount our actuator and brackets to the window. A metal brace was welded to the car for support and attached to the back of the sub box to ensure it was secure. Once we calculated the precise angles, we attached the brackets, mounted the window and hooked up the 24” liner actuator. Presto.. the windows were moving on their own. We then attached a 2 Channel wireless remote to these actuators so all movements could be done remotely away from the car. Once the window was moving up and down we created our mounts for the amps. We cut ¾” MDF blocks which the amps would be mounted to. We had to make sure that the amps sat flush with the car so that the windows could close perfectly. To finish off the amp install we stretched a piece of fleece over the amps to give us a nice contoured panel that flowed with the exterior of the car. We bondoed, sanded, primed and painted it.
