Ever wanted to learn the techniques used to cut a 'port' from the cab to the box of the truck? Well this is it. The purpose of porting through is to locate sub-woofers of the stereo in the box of the pick-up, in order to maintain leg room in the cab of the truck while enhancing your stereo's performance dramatically.
The first step is to make sure that all tools and supplies are present.
Required for this project is a small jigsaw with a metal cutting blade, a drill, 1/8" and 1/4" drill bits, an accordion gasket, and a large compass to draw a circle.
The accordion gasket can be picked up at any auto parts store for around $15/ft. can.
This truck is getting a 14" circular hole cut so 4.5' of gasket is required. Silicone or urethane is required to seal the joint, and it is a good idea to also seal the gasket to the sheet metal with either of these.
First mark the hole on the inside of the box. When you have this hole marked, drill a 1/8" hole dead centre of the circle. Be sure to drill through the box and the cab of the truck.
Next, go inside and mark the circle on the inside of the cab. Does this circle draw nicely without hitting any major supports in the cab? Keep in mind that you need 1/2" above and below the circle to attach the gasket to.
Now you can cut your hole, so drill a 1/4" hole at the top of both circles. Set your jigsaw so that it won't hit both pieces of steel and using your 1/4" starter holes cut out your circles.
The accordion gasket clips on to both sides of your opening, so after making sure it is cut to the proper length, run your bead of sealant and install the gasket.
Now measure your cut out onto the carpet inside the cab of the truck, cut a 13 3/4" hole into it and sew a new piece of carpet, approximately 6" wide around this opening.
Reinstall this set-up into the truck and you have created a fully carpeted port through.
