Update: The IB wall and amp rack are complete. It is quite similar to the setup I had in my 2010 Passat (if it ain't broke... :D ) with a few changes, and far better fabrication thanks to Jon and the crew at Handcrafted Car Audio in Chandler.
I requested that the grill design take cues from the Audi RS4 grill. I also requested that I retain access to the floor hooks for the storage net. The corners are sealed off on the back side of the baffle.
The IB wall is 4" thick- a double 3/4" baffle, followed by another two layers of 3/4" for reinforcement and excursion clearance, and a double 1/2" grill layer over the front. The grill is still being finished as we are waiting on mesh and Audi rings.
The amp rack is constructed from aluminum sheet. The tolerances were incredibly tight with all the gear and the sub motor, especially pushing the IB wall far enough in to the trunk that I could retain most of my trunk space. Here is the test fitting:
One thing I didn't do in the Passat was seal the rear deck. I decided to do that in the S4. Jon removed the factory subwoofer and made ABS templates of the exposed holes for the sub and others that were stamped into the rear deck, securing them in place with adhesive, then finishing with the same dampener treatment that the front doors received.
The baffle was finished in black/charcoal carpet that closely matches the factory trunk liner, with the grill trim finished in the same black vinyl that was used on the kick panels. The grill insert will be heavy gauge honeycomb mesh, and hopefully will incorporate some Audi rings to mimic the factory grill. :) Still sorting out details on that.
The amps were modified to be internally bridged, to bypass all the filters, and have fixed gains, so no access to the terminals is needed after initial install, which makes for a clean look and allows the wiring to be hidden (still wiring things up at the time these pics were taken):
Two Gladen xs75c6 on the upper level (L+R) which will each run their respective side of the front stage. A single Gladen SPL1800c1 is centered beneath the sub it will power. I really like the symmetry of this. A Mosconi 6to8 Aerospace is on the driver side for processing, and distribution is on the passenger side. The moBridge DA3 is installed next to the factory amp where it converts the MOST signal to SPDIF.
The aluminum rack is secured to the trunk floor with rivnuts. It doubles as a lower support brace for the IB wall, with four 90* tabs extending off the back side of the base that are bolted to the baffle. The top of the baffle is secured with two large, thick gauge brackets that are bolted to the underside of the rear deck and flank the subwoofer on the baffle.
And here is the behemoth- the B&C 18DS115, in its new home, surrounded by the RS4-inspired grill. The baffle is surrounded on its perimeter with high density foam for a snug fit, and I'll probably reinforce a few areas in the corners if I have any audible "leakage" so to speak. Overall, it's solid as a rock!
I ordered some custom-length RCAs last night that use Mogami 2964 cable and Neutrik-Rean NYS connectors. I'll have to pull the rack to wire everything up, then re-install. I also need to use VCDS to change the setting in the Audio menu that allows the MOST signal to be used by the DA3. I am hoping to have this up and running by next week. :cool:
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