Project [IBWALL] 1998 Toyota Hiace

5 years 10 months ago #1 by Tiger
OK, this van concept was something that a friend of mine had been thinking about for a while. Build a campervan with a setup that will take stuff-all room. How? Infinite Baffle wall. I was all for it from the start, but two other friends were trying to tell us it was impractical and Eric (my friend who owns the van) started agreeing with it. I said I want to build it. Full stop. Not long after, the van wasnt bought first.... these were:

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The bargain of the century with all 8 x 15 subs for $AUD350!!!! hahahaha.

The van followed suit afterwards:

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Shortly after, he acquired his front stage (for now):

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2 x MaxAV Pro Audio 10s and Quantum Audio 1.75" Pro Audio Super Tweeters.

I quickly jigsawed out the doors and the boys cut out the speaker baffles. I "brainsed up" the baffle lay out But now the work left for me is to turn the doors into actual finished doortrims (we are NOT leaving them ghetto like that!)

Until then.... we prepped the van for some MUCH needed deadening.

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5 years 10 months ago #2 by Tiger

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And that's what 2 packs of deadener does for you.


Now for the fun part.... frame work :)
5 years 10 months ago #3 by Tiger

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Because I was working for a polystyrene cladding company a while ago (when this project first started), I gained access to some inustrial expanding foam. (The gun for the foam is worth $80AUD alone! Cartridges are $25 each and the gun cleaner is another $25. That's wholesale pricing!) But, they let me use some... so I did! :)

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5 years 10 months ago - 5 years 10 months ago #4 by Tiger
Day two:

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^^^ And that is one round down....

We then anchored it down SOLID in three spots and this bracing arrangement is seriously going NOWHERE anytime soon!!!!
5 years 10 months ago - 5 years 10 months ago #5 by Tiger
Next round... same day:

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^^^ This is Eric... I've already worn him out by this stage, but seeing the wall potential was the driving force to keeping him going. :P haha

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^^^ Me in action with the gun foam. (I love the suff!)

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And now for the tough stance shot to end the day!

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Day two..... done and dusted. This frame is bolted down THAT sturdy that you could use it for a stripper session and swing off the thing! Exactly what we needed for this kind of application. The cabin needs to be well sealed off... and rock solid to prevent wall flex.
5 years 10 months ago - 5 years 10 months ago #6 by Tiger
Next session:

Foam clean up

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OK... template is set.... now... time to face reality... we are about to mount 8 x 15s in a workhorse!!! :/

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WHAT THE FACK!?!?!

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Trial fit time...

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Looks pretty damn intimidating!!! But nevertheless.... loving the look of the progress so far! :)
5 years 10 months ago - 5 years 10 months ago #7 by Tiger
After we ripped out the wall, I started on sealing the side of the wall off from the cabin...

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... then Eric ran his wiring harness for his Behringer processor (which will be roofmounted eventually)

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OK.... roof liner work.

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And me back into the side wall seal..... PAIN IN THE REAR!!!!

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I then took a breather and started having some fun with the wall baffles :)

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Eric then carpetted the side wall seals while I was on the router with the wall.

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Looking clean :)
5 years 10 months ago #8 by Tiger

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^^^ This little piece is never seen.... but REALLY needed, and you'll be shown were it goes later. I quickly fixed this up for Eric to carpet also.

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This is where it goes. Behind the passenger seat. It is where the door latches onto the inside of the van opening. That needed sealing (and clearance at the same time)

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And that's how all the side wall seal comes together :)
5 years 10 months ago #9 by Tiger
OK, trimming pics. This is Eric in action, while I was on the router doing the baffles.

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Coming along JUST fine :)

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This part sucked a$$!

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Shot bearing on the router bit. Back to Bunnings I go. I was able to buy a 13mm bearing for it so it worked out a quick and cheap repair. PLAY ON!!!

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5 years 10 months ago #10 by Tiger

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NOW... fun part... the wall is being mounted with insert nuts, so that way it's still completely removable!

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And then.....

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We have an IB WALL! :)
5 years 10 months ago #11 by Tiger
That's all for now, I'll throw up some more posts later on tonight. The roof mounting, the dash and doors :) It's a massive project that is still in the works. But, can you tell it's my first walled build with the amount of pics :P hahaha
5 years 10 months ago #12 by Tiger
While I was working on my own mad creations, Eric got to finishing off the roof lining.... and a few other things.

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And for the sake of testing the cameras, he temp fitted one camera that view inside the entire back of the van (incase anything flies in the back or becomes untied in transit somewhere... or if he wants to lock people up in the back of the van and have the bass killing them and he can sadistically watch it all unfold in cabin! (MWUAHAHAHAHA)... you get my point

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and temp fitted the reversing camera :) All works well.

Now.... my show and tell ;)

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5 years 10 months ago #13 by Tiger

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[imghttp://img688.imageshack.us/img688/1217/imag0616n.jpg][/img]

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I'm happy with that for now... onto the doors again...
5 years 10 months ago #14 by Tiger

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From a 6mm template to a much needed 18mm door card!!

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Yes, as the mad man that I am... I recessed all that with no guides... and surpising didn't pop a hole through the middle! But... because of this... It now sits hard up against the door skin VERY happy with it

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A little mapping out on what needs to go where... this is where the door build becomes interesting....

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5 years 10 months ago - 5 years 10 months ago #15 by Tiger

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And BAM! 2 x 10s in some crazy a$$ door cards!!! haha

To give you an insight as to how confident I get on a router (or any tool that modifies MDF in any shape or form), I have had to do work oin this van without guides... such as the following...

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Not bad for router work WITHOUT a jig or a guide! Anyways... back on topic... next door!!!
5 years 10 months ago #16 by Tiger

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Door 2 done :)

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Lights wiring run through the door now and ready to roll.

NOW.... back to the dash ;)

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After firing up the windscreen demister, it works just fiiine! :) According to our local laws, a car can have a modified/custom dashboard, PROVIDING the demister works and the instrument cluster is present and functional. VERY happy to learn that.

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???
5 years 10 months ago #17 by Tiger

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Starting to take serious shape now :)

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MUCH better!!!!
5 years 10 months ago #18 by Tiger

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Amazing what a small roundover does to a speaker pod :)

OK.... new template....

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Then the doors needed some finishing off..

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These doors got a treatment of thin MLV sheets.. and WHAT a difference this made with the deadener included on these 18mm MDF trimmed doors!

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Then..... we grew impatient.... and wanted to get this beast OUT!!! And then the following happened!

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^^^ Highway Patrol is behind the van :p

After I finished the Alfa, Eric and I just wanted sound from this van once and for all.So we through everything in and Eric played around with the Behringer like a husband plays with his newly married wife on his wedding night! :P Quite a few twealks and needless to say, this van is an extreme SQ vehicle more than it is a groundpounder. I can't believe how accurate this thing plays and it's imaging is insane! We agreed to take the van out for a spin to get food... which then turned into a Lygon Street lap. Eric plays a bit of DJ Billy E - Beats For My Van (fitting track! haha) and heads turned. In the passenger seat, I just watched people snap their necks wondering where on earth the major low sine wave was coming from! And the subs weren't moving much either. But the wall just gets effortlessly loud and clean at the same time. 10 minutes later.... we see flashing lights in the side mirrors. "Just a random license check" SURE! We were targetted! Apparently, Eric's license expired about 2 or 3 weeks ago and he din't realise it.... and we were told what the hell was the loud music all about and to please turn it down. We were "disturbing the peace". :P

So that was our highlight for the night!

And this is where the project is at, at this point in time.

For everybody's information, The 8 x 15s will be powered by an Earthquake PHD10000/1 at 2ohm and the 2 x 10s are paralleled to 4ohm on a Cadence A4 4 Channel bridged at 4ohm. A matching 4 channel runs the high and mids. The head unit is the new Pioneer AVH-8450BT.

Back with more soon enough... and hopefully some vids! :) I've heard rumors that it's doing 15Hz shirt tricks! hehehe

Thanks for viewing the thread so far :)
5 years 10 months ago #19 by Tezzating
Thats pretty awesome, I think IB walling is a real smart idea if you're not going to do a full on extreme wall install in a van like that. Look at all the room you have for puppies and candy now.. :D

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5 years 10 months ago #20 by amcinstaller
that is awesome. there really isnt any other words to describe it. you guys really go all out!
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