We are kicking off the second chapter of Project: Broken Silence by diving into the Sony Mobile ES audio system design. Next, we’ll explore how the new amplifiers, speakers, and subwoofer integrate with the factory-installed infotainment system. Finally, we’ll examine how Broken Silence Custom Car Audio prepared the vehicle by installing SoundShield sound deadening materials and running wires for the new speakers.
Project: Broken Silence Audio System Design
Choosing the 2024 Ford Mustang Dark Horse was a deliberate decision for this project. This choice connects to Sony-sponsored NASCAR Cup Series driver Ryan Preece and showcases the audio system performance upgrade capabilities of Sony’s Mobile ES products. The Mustang is an excellent vehicle for demonstrating these enhancements.
The Mustang’s front speakers can easily be replaced with the XS-163ES 6.5-inch three-way speaker set. The woofers and midrange drivers fit the factory door speaker locations. Soon, we’ll see how Broken Silence integrates the tweeters. In the rear, the XS-160ES 6.5-inch coaxial speakers are an ideal upgrade for the speakers on the rear parcel shelf.
The Sony XS-W104ES 10-inch subwoofers will deliver impressive bass output from relatively compact enclosures. This feature is crucial, as many subwoofers are often installed in undersized enclosures that hinder their low-frequency output. Since the Mustang’s trunk doesn’t offer the same space as a large SUV, maximizing the available space is essential.
Dual Amplifier System Design
High-end home audio enthusiasts may be familiar with the dual-mono amplifier system design. Instead of a single stereo amp, these systems use a dedicated amp for the left speaker and another for the right, maximizing stereo separation and creating a wide soundstage. The audio system design for Project: Broken Silence emulates this approach, using a pair of five-channel Sony Mobile ES XS-5ES amplifiers – one dedicated to the left speakers and a subwoofer, and the other amp powers the right speakers and a second subwoofer.
The XS-5ES amplifiers are rated to produce 100 watts of continuous power per channel for the four main outputs and 450 watts for the subwoofer output. These specifications apply to four-ohm loads.
The XS-W104ES subwoofers, rated to handle 450 watts of power, are a perfect match. The XS-163ES and XS-160ES speaker sets also pair exceptionally well, power-wise.
Another benefit of this amplification choice is its impact on system design symmetry. Installing two identically sized amplifiers in a vehicle is much easier and visually appealing.
Factory Radio Integration
Although the Mobile ES line includes two exceptional source units, replacing the radio or infotainment system in many new vehicles is challenging or impossible. The Mustang exemplifies this scenario with its 12.4-inch LCD screen in front of the driver and a 13.2-inch screen to the right for climate control, infotainment, and vehicle settings. This vehicle needs a superior audio system, but the upgrade must work with the factory-installed radio.
B.J. Curcio is collaborating with the team at mObridge in Australia to develop a solution to extract an analog audio signal from the networked information connecting the OE infotainment system to the factory-installed amplifier. Solutions like this are the foundation for most audio system upgrades.
Building the Foundation: Sound Deadening
Two critical first steps in premium car audio system upgrades are treating the vehicle with sound deadening and running upgraded wiring for new speakers. Sony partnered with SoundShield to help make the interior of the Dark Horse Mustang quieter. They provided four 11-square-foot tubes of triple-layer sound-deadening material for the project. SoundShield deadening features a high-tack adhesive to ensure it remains bonded to the vehicle even in extreme temperatures. The top foam layer helps to prevent buzzes and rattles from trim panels and wire harnesses.
Adan from Broken Silence Custom Car Audio began by removing the interior door trim panels and thoroughly cleaning the surfaces before applying the SoundShield. He started with a deadening layer on the outer door skin to help reduce road and wind noise. Next, he applied a layer to the inner door skin, trimming all the holes for wiring harnesses and putting them back in place to ensure everything would function perfectly upon reassembly.
Speaker Wire Installation
Running new speaker wires is essential if you’re serious about delivering maximum power from your new amplifiers to the speakers. Broken Silence ran two sets of speaker wires into each door. All the wiring is secured to the factory harness with cable ties, ensuring the new wiring stays in place and doesn’t buzz or rattle. Additionally, knowing the wiring will remain secure makes reinstalling the trim panels much easier.
Follow Project: Broken Silence
As you can see, progress on the Mustang continues. The vehicle is now ready for the installation of the Sony Mobile ES speakers. The construction of the subwoofer enclosure and the amp rack will follow shortly. Be sure to follow along as we document this demo vehicle build for the 2024 SEMA Show in Las Vegas.
