Can I fit a Xenon 200.4 under a hidden panel in my Forester

Me-262 · Post by **Me-262** » Mon Dec 10, 2007 6:23 pm

Hey guys, its time to build my amp rack in the Forester. The original plan was to put a ZX450 in there just like in my wife's. It fits, it works, its simple. Then I found out HoseHead had a Xenon 200.4 and the little wheels upstairs started to churn.

The Forester hatch has a few hidden compartments build in using foam. They waste a lot of space so the potential to replace the foam with an amp rack is there. I'm going to replace the Left side panel, its long and wide enough for a 200.4 to just fit and all the wires to clear. Here's where its going to get tricky, the center panel that covers the spare tire rests on a portion of the left panel. The amp rack will have top plate which I'll cover in carpet so it all looks OEM to the casual observer and I'll be able to use the hatch area to stow gear.

I'll be throwing all sorts of stuff in the hatch so the amp rack will have to support the weight. Probably the heaviest thing will be the race tires, about 150lbs distributed over the entire hatch area with seats down. My biggest problem will be supporting the top cover, with the 200.4 in place it takes up most of the room so I'm not sure if/how to support weight and build stand-offs. That's where I'll count on you guys for the experience and ideas. I want to keep it simple and as lightweight as possible, no fiberglass or bondo.

This is the left panel I'll be replacing with an amp rack. You can see the bare foam on the right hand side on which the center spare tire lid rests.

The base of the amp rack cut out. I used 1/2 inch plywood and I plan on using the same for the lid. With proper supports I should be able to lean on this and store gear without cracking it. I'll screw it down into the metal to keep it from moving.

Shots of the 200.4 in place with/without the center panel in place

Various shots of the 200.4 to give you an idea of what space I have left to build stand-offs/supports

Rear bumper side

This is the side right up against the rear seats. There's just enough room to run the speaker wires out and to the side.

Left side against seats

This shot gives you an idea of how much clearance I'll have between the amp and the top rack. The amp is under the plastic, that ribbed thing is the spare tire. Its not much space but with the fans I don't see overheating an issue. I have a simular install with a ZX450 in my wife's car and it never overheats.

So how would you go about supporting the weight and install the top rack ? I'm planning on screwing it down to keep it in place.

I took a little descriptive video of the whole deal to give another perspective. I have the ZX450 so I don't have to run a Xenon 200.4 but it would be nice. Let me know if its possible, suggest away.

444 FED · Post by **444 FED** » Mon Dec 10, 2007 8:32 pm

I would most likely use a piece of angle iron, or maybe a couple pieces to provide a gusset, that will support the trim cover. You can place it along the edge of the panel, or if there is clearance under the middle of the panel.

Post by **stipud** » Tue Dec 11, 2007 7:56 am

Phew... looks like a pretty big trial and error job to me. Don't think there's any textbook method I can suggest.

Have you considered hollowing out the foam to fit over the end of the amp? That would provide the support you need, but it may squeeze on the amp a bit.

Alternatively if you get your templates accurate enough, you could use thinner metal to throw this all together, which would give you some more room for brackets and such. Of course they would need to be welded to fit properly, so you would have to have all your brackets lined up and marked, then take it somewhere to be welded (unless you can do that yourself).

Those cars have a full size spare? That's pretty cool... and it gives you much more vertical room to play with.

HoseHead · Post by **HoseHead** » Tue Dec 11, 2007 8:46 am

Nice amp.

I have some ideas, but no time right now to pen them.

Later.......

Post by **Bfowler** » Tue Dec 11, 2007 9:01 am

I love all the videos latly! (btw, the word is not abuoot

)

i think your best bet as you suggested is some metal "L" brackets

how much space is between the back of the amp and the larger panel (4th picture)

maybe you could make a long steel support that bolts to the bottom of the middle panel that the one that covers the amp can sit on?

Post by **stipud** » Tue Dec 11, 2007 9:05 am

Bfowler wrote:i think your best bet as you suggested is some metal "L" brackets

That got me thinking too... if you can find some U brackets big enough to go around the amp, you will be in business. I recall seeing them once upon a time... 3x3x3" I think it was. You could just run that along the side of the amp, maybe put some foam up top to take care of clearance issues, and shazam!

Me-262 · Post by **Me-262** » Wed Dec 12, 2007 7:46 pm

stipud wrote:
Bfowler wrote:i think your best bet as you suggested is some metal "L" brackets
That got me thinking too... if you can find some U brackets big enough to go around the amp, you will be in business. I recall seeing them once upon a time... 3x3x3" I think it was. You could just run that along the side of the amp, maybe put some foam up top to take care of clearance issues, and shazam!

Where in Canada could I find such U brackets ?

Post by **mr tibbs** » Wed Dec 12, 2007 8:22 pm

Have you thought of doing some glassing? That should be strong enough to do what you are after.

Post by **stipud** » Thu Dec 13, 2007 7:30 am

Me-262 wrote:Where in Canada could I find such U brackets ?

I remember going to a huge steel factory long ago with my friend, trying to find some various pieces to mount some Dodge Shadow seats in his 1977 1500... They had piles upon piles of all kinds of metal brackets, so we scoured the fields of metal and finally found some bars that worked. I recall seeing all shapes and sizes of U, J, L, I, []... you name it.

Alternatively you could have them cut one edge off of a square beam as well... but that may be troublesome.

Fiberglass is actually a pretty good idea, and you could make it pretty too!

444 FED · Post by **444 FED** » Thu Dec 13, 2007 6:18 pm

The best sig EVAR!! HAHAHAHA

MW3 · Post by **MW3** » Thu Dec 13, 2007 10:24 pm

Sure is a pretty amp to hide.

Post by **Bfowler** » Fri Dec 14, 2007 9:06 am

444 FED wrote:The best sig EVAR!! HAHAHAHA

hehe, i'm glad someone picked up on that

444 FED · Post by **444 FED** » Fri Dec 14, 2007 9:48 am

I've actually borrowed it and used it on another site.

I friggen love it!

444 FED · Post by **444 FED** » Fri Dec 14, 2007 9:52 am

Back on topic....

You can easily make a frame work out of angle iron, even better if you have the facilities to weld. You can make it so that there is a trim panel and only a small removable cover panel to make it look nice.

Me-262 · Post by **Me-262** » Sat Dec 15, 2007 8:00 am

One of the guys in our Subie club is a machinist, I'm going to bounce some ideas off him. With the U bracket, how would you place it on the bottom template. Facing down as in the shape of a U ?

444 FED · Post by **444 FED** » Sat Dec 15, 2007 9:48 am

Probably sideways, more like a "C" would make more sense, so that there is a flange on the base and and a flange on the top to support the cover.

dedlyjedly · Post by **dedlyjedly** » Sat Dec 15, 2007 12:27 pm

^^^exactly. just measure the height of the foam that previously supported the panel and you've got a target height of the new brackets. You may be able to find some c-channel that's the right height when you turn it on it's side. If not, get one that's two big and it could be chopped down and welded back together.

Post by **Bfowler** » Sun Dec 16, 2007 12:24 am

ok, i think i figured it out.... but some L shaped steel at a hardwarestore. (like the length of the am plus a few inches

bolt two ~2inch lengths at either end of the amp flat side down and then bolt the long length to the back of both of them at either end so you end up with a lip that spans over the whole amp

I made a crappy pic....yellow is a Bolt. red is the long legth and blue is the short end pieces...i hope it makes some sort of sense...