siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianstockgrilltabs.jpg"></center><p>First I popped out the factory grille. There are four tabs on the back. A few nips with some needle nose pliers and the grill was free....

siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianstockgrillremoved.jpg"></center><p>here's the grill removed. Not much room to work with there... eh'?

siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberiansaranprep.jpg"></center><p>In order to contour the backplate so it matches the stock door panel, I decided to make a mimick plate using fiberglass cloth and resin.

First I laid plain old kitchen Saran Wrap over the area to keep any resin from leaking onto the panel itself

siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianfoilprep.jpg"></center><p>next, over the saran wrap, I put down a layer of tin foil. This is because I could form it into the crevices and it would hold it's shape.

siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianfiberclothprep.jpg"></center><p>Next, I put down a layer of fiberglass cloth. This stuff is a little thicker and heavier than grille cloth. I figured it would hold more resin, and be sturdier in the long run.

siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianresindrying.jpg"></center><p>I taped everything down with duck tape to make sure nothing moved while it was drying... then I soaked the whole thing with bondo brand polyester resin. YOu have to work fast with this stuff... you start painting it on, then five minutes later, the stuff is hard!

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<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianroughbackplate.jpg"></center><p>after it was dried, I removed the whole thing from the door... thanks to the first layer of saran wrap, it just pulled right off with the tape.

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<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianroughcutbackplates.jpg"></center><p>then I trimmed the general outline of the backplate to keep it compact.

siberian

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianhardboardrings.jpg"></center><p>now it's time to work on the speaker baffles.

first I cut two rings out of 1/4" hardboard. I used a router with a circle cutting guide rather than a jigsaw. This way, I was able to achieve perfectly round circles.

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<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/siberianbaffles.jpg"></center><p>next, I used cabinet edging strips. It's that oak stuff with the glue on the back. You glue it to the edge of a counter top with an iron. Anyway, I wrapped it around the wood rings three times to thicken the walls up a little, then heated the glue up with an iron to hold it all in place. I also popped a few staples in there to reinforce it.