MSA's 2013 SEMA Project: Black Rhino > Speaker Pods - The Design

The speaker pods have been an amazing feat from the get go.  I'll explain how speaker pods are normally made and a new method I tried out that worked great for me.  First off, we didn't want to build something simple.  Sponsors don't want that.  They want their products displayed, not hidden.  They want flashy, showy, attention drawing exposure.  I'll write a blog later on sponsors - how to get them, what they expect, and the understanding of what comes with that.

Front Doors:
So, we had a small challenge to overcome here.  We definitely wanted to incorporate as much sound awesome-ness as possible.  We chose a set of 3 way components for each door.  However, Fords are known for not having a lot speaker space.  Some nice deep pockets are available, but everyone does the same...mold the speakers using the whole door panel and rock on.  Just perhaps the speakers in different spots, but most are about the same.  Nah.  I wanted technical credit.  Not SQ, but "cool" credit.  So, I chose to keep as MUCH of all the pockets as possible.  After all, we are still using this truck daily.  We chose to put the speaker pods in front of the pockets.  However, we were faced with the challenge that when the doors closed, the dash would hit.  So we had to be careful where exactly we put the speakers.  I wanted them to look like they were a part or at least a continuation of the factory piece.

Rear Doors:
These doors are a bit more challenging.  First, the speakers sit behind the back seats and to the side.  If you've owned a Ford truck, this design hasn't changed in years.  Because of Ford's design, there are no speaker wires going into the back doors, nor is there any room.  There were 2 additional factors that came into effect here.  One, we are doing Suicide doors.  We had to make sure where ever we put them, the doors still worked.  Second, I have little kids, and those speakers had to be protected.  So the only spot I was left with was inside one of the door pockets.  I decided then to replace the front door pocket with the speakers with pods that were isolated.  Basically, instead of molding the speakers into the door panels, like most do, but trimming the panel to meet up with the speaker pods.  Technical...I think so.  Trimming a plastic door panel very closely is not an easy task.

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MSA's 2013 SEMA Project: Black Rhino > Corrected Airbags Arrive / Fab work begins

Recap: We ordered and received a lot of wrong parts.  Not at the fault of the sponsor, but somewhere there were some miscommunication.  The rear setup allowed us to go low.  Body drop low, which is great, but with us having BedRug and Bedslide as sponsors, we didn't want to notch and cut the bed.  So that was a no go.  The front suspension, being a 4WD, proved to be a difficult task, and after lots of cutting and trimming, we got the truck's transfer case to sit inches from the oil pan.  No problem, except the bracket setup for the front is for a 2WD, and the setup with bags didn't even fill the gap at the trucks lowest position.  There in lied our issue.

So, here we are 2 weeks before D-Day and our correct parts arrive (10/17/13).  So we have to fabricate and create a complete airbag suspension set up.  That wouldn't be a big deal, but....there's just such a long list of things to do that it set us up for long days ahead.  In addition, our wheels hadn't arrived.  The wheels are brand new for 2014 release, so they were being made specifically for our vehicle.  That's a whole 'nother story.  :D

So over the next few days, we fitted, measured, tacked, cut, fitted, measured, and made everything where we wanted.  It looks great.  The parallel bars were in place.  The compressor/valve housing had been made the week prior.  Many endless nights of cutting, welding, grinding, buying and finding scrap metal...  A Spcial thanks to our friends at Conway Precision Products.  Because of them, we were able to get a LOT of our metal.  We were rocking and rolling, and....then wheels finally arrive on 10.21.13.  Uh oh...
to be continued...

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MSA's 2013 SEMA Project: Black Rhino > Airbag Parts Arrive

Finally...all our airbag components have finally arrived.  Opening these packages were a relief.  The schedule is extremely tight, and we will use every second to complete the project.  We hoped that the airbags would have arrived a week or two ago.  But with the setbacks on the suicide doors, it wasn't a problem to receive them a little later.  The brackets and all the components looked great.  When we finally received the setup, we noticed the back bag brackets weren't correct.  Another kink in the chain.  Somehow there was some miscommunication, and we ordered the incorrect parts.

The rear brackets were made with the bags on the outside of the frame, therefore placing them closer to the wheels.  Not having received wheels yet, we weren't entirely sure this would clear the setup.  Especially since the vehicle will be sporting 24" wheels.  The front brackets were too short and are the setup for 2wd vehicles and not our 4wd.

Grant it, we are able to fabricate our own parts and create a system completely outlandish.  But time wouldn't allow it.  Being a 2014, we were only able to take delivery of the vehicle a month ago.  Purchasing parts that were fabbed for the truck was our quickest route.

So the challenge we face is this.  We cannot cut a hole in the bed, nor can we raise the floor.  BedSlide and BedRug are both listed as sponsors.  Both products must be in the vehicle, and although we are building a custom truck, we want to retain as much of the product's originality as possible.  Then again, this is a 4wd vehicle that has to go LOW.  So the logistics of such as build has been challenging.  We, however, have made forward progress.  The front has been cut, trimmed, and shaved to get it at its lowest point.  When the airbags are fully deflated, the oil pan will sit just a hair above the transfer case.  We have maxed the limits.

No kink that can't be handled.  Just another part of the SEMA woes...  It happens.  Continue to rock on.

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MSA's 2013 SEMA Project: Black Rhino > Suicide Doors...1 door roughed in.

Finally! After doing and redoing, we have a working and functioning Passenger rear door. The body lines are perfect. The door doesn't have any play in it anymore, and it opens and closes just as smooth as it used to, but in reverse fashion.  So stoked...other side shouldn't give us any problems.

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MSA's 2013 SEMA Project: Black Rhino > Suicide Doors...the saga continues

Well...nothing ever seems to go smoothly when you're talking about a completely custom setup.  The Suicide Doors have been redone a few times now to make sure it's form and function is exact.  The doors open like they should, they hold like they should, and that they will withstand the abuse of daily use.  After installing them, we found the metal in the pocket it wasn't thick and sturdy enough, allowing the door to have some play.  The skin we replaced on the doors were too far out, not allowing the hinge bolts to sit flush against the door.  So what do you do?...  Cut it out and start over with stronger materials and create new template for the other side.  Being a newer product we haven't used before, it's always trial and error.

The spacers that were sent with the kit are useful...if perhaps you had a really light door.  The spacers allowed for some flex, so we had to recreate a pocket that eliminated the spacers.  Compound angles. Fitment and testing.  All requires time and patience.  But in the end, it's always worth it.

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MSA's 2013 SEMA Build: Black Rhino > The Engine Bay

Changing The Engine Bay Color

The Truck came in white.  So one of the challenges was to make sure zero white remained on the vehicle.  Under the hood, in the door jams...anywhere there was white had to be eliminated.  We considered the prospect of creating engine cover panels like old school hot rods/street rods have.  Looking at mounting points, we ended up throwing that out the window and started to remove components of the engine.  For simplicity's sake, we removed crucial parts, taped off the remaining attached parts, and painted anything white a semigloss black.  While in there, the wires were ran, loomed, and prepped for the Rigid Industries light bars, the airbags, and the audio system.  Rockin' and Rollin'.  The Countdown continues.

Changing the Engine Bays' Color

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MSA's 2013 SEMA Project: Black Rhino > Dropping The Front

The largest dilemma in any bagged setup is to make sure when the bags are deflated, the vehicle rests where the builder wants it. When researching, DJM and a few other companies created lowering kits for these trucks...BUT only in 2WD. There were no 2WD kits, and with my unfortunate luck, there were only 4WD vehicles in a 100 dealership radius.  So the challenge of actually bagging a 4WD F350 was presented to us. Good thing we aren't strangers of challenges nor are we scared of them.

The largest challenege: the transfer case. After removing the suspension, bump stops, bump stop brackets, and a few other components, we were left with the transfer case touching the cross member. That was our lowest point and we still had a few inches to go.  So we had to make a few...adjustments.  The I beams were shaved down. The top of the transfer case was shaved down. And...we cut out a hole in the cross member for the transfer case to fit perfectly inside.


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