This procedure provides sound deadening as opposed to simply stopping resonance which is what products like Dynamat accomplish. It is not necessary to cover every surface of the door, floor and trunk. This simply adds weight to the car. The CLD tiles (or even Dynamat) will reduce vibration and resonance. However, It is not a very good sound barrier. While the door will no longer resonate with the tiles, you will still hear road noise. The goal is to use the sound dampening panels in strategic places and then create a sound barrier using the MLV (mass loaded vinyl) sheet.

The following instructions has been compiled from posts at Kappaperformance.com

The materials needed are as follows and can be purchased from the author's web site:

http://www.sounddeadenershowdown.com

45 CLD Tiles
1 roll Extruded Butyl Rope
1 67.5 ft roll MLV
3 sheets 1/4" CCF
1 Velcro Patches, adhesive 2 sides,
1 8 oz can HH-66 Vinyl Cement

The following instructions are from Kappaperformance.com

http://kappaperformance.com/index.php?topic=2450.0

Wyatt (TecSolOnt) managed to get some CCF behind the MLV on the back wall. This is a good idea. I'm not sure if he used scraps or something else, but you might want to add another sheet of 1/4" CCF for that. Scraps of CCF are very handing for stuffing behind other trim panels as well.

The MLV roll is 54" wide which works out very well for this project. Cut two 18" pieces for the the doors and trim the length to 37". The back wall wants a 36"X54" slice. The floor needs two 26"X54" pieces.

Two of the CCF sheets should be cut 20"X54" for the floor. Reserve the 16"X54" piece for the doors. The third sheet goes into the trunk.

CLD Tile distribution is pretty simple: 5 each outer door skin. Cut 1 tile into smaller pieces for the inner door skin. The floor gets 14 (remove the stock deadener first) distributed over the resonant, unsupported areas. 4 for the back wall and 9 for the trunk.

If you want to treat less than the full car, let me know and I'll figure out what you need.

I'll throw in a set of the aluminum "Africa " pieces (door inner skin access hole covers) to anyone who buys the material to treat their doors and at least one other area of the car.

Doors
First you have to take them apart. Disconnect the negative battery terminal. Remove the Phillips head screw on the end of the door.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_01.jpg

 

Unclip this cover by moving the tab (to the left on this side) and pulling the cover out.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_02.jpg

 

Remove the Phillips head behind the cover.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_03.jpg

 

Pop out this panel.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_04.jpg


Remove the 2 bolt head screws.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_05.jpg

 

The trim panel is now only held in place by plastic clips. Pull it straight out, starting at the bottom. A panel popper will be very helpful. When it come free lift it over the lock knob to give yourself some space and disconnect the wire harness connectors and the door handle cable.

Peel off the vapor guard and throw it away. The adhesive is a very gooey butyl compound. The best way to clean it up is to roll some up into a ball and use that to poke at the adhesive still on the door. It will pull it right off.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_06.jpg


Remove the bolt head screw at the top of the speaker.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_08.jpg

 



Pull the top of the speaker away from the door until you hit the clip. Press down on the clip from the top to release the speaker. Disconnect the wire harness.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_09.jpg

 



Working through the large access hole, remove the black Styrofoam block. There are 3 Christmas tree clips holding it in place. Work them free with a screwdriver or panel popper and work the block out of the door. You will be putting this back after applying CLD Tiles to the exterior sheet metal. Don't Forget!

Grab hold of the stock butyl/foil vibration damper and pull it out. We'll be replacing it with something much more effective. Pick out any butyl that separates from the foil.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_10.jpg


Here's what the block looks like out of the car


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/dis_11.jpg

 


Now you're ready to install the materials in the door kit.

 

Door Kit - Part 2

Time to install the CLD Tiles to the exterior door skin. You will be installing 3 tiles above the crash intrusion protection structure and a 4th - cut in half along its length. Wipe down the surface with denatured alcohol to remove dirt and any greasy residue. No matter how clean your car is, the insides of your doors are probably dirty.

The best way to install the tiles is to peel back an inch or so of the release paper, press the tile in place and start peeling and pressing until you have the paper completely off. You don't want any air bubbles between the tile and the sheet metal. Go over the tile with a roller.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/tiles.jpg

 



Put the Styrofoam block back in

To seal or not to seal?
I always seal the access holes in the doors I work on. The advantages are that it reduces noise transmission, makes the door more rigid and less resonant and turns your door into something closer to a proper speaker enclosure. The down side is that the edges of the holes aren't all in one plane so you can't just cut a piece of aluminum stock and screw it in place unless you are pretty good at shaping sheet metal. You can do this with a variety of materials but you want the covers to be as rigid as possible, waterproof, non-corroding and removable.

I made fiberglass covers for the doors. This is a good way to go but it is very time consuming. I'm not going to show the details of how I built them because I really don't want to encourage anybody to do this unless they have experience working with the stuff.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/fg.jpg

 



John and I did his doors using a double layer of aluminum flashing you can buy in the roofing department at Home Depot with a layer of butyl between the two layers of aluminum. This isn't as rigid as fiberglass, but you can cut the flashing with heavy scissors. The sandwich is flexible enough to be pushed into the contours and the butyl layer makes it very non-resonant. This image also shows how you should cut up and apply a CLD Tile to the interior door skin.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/flashing.jpg

 

Here's how to make the flashing "sandwich". Cut your 2 matching pieces of flashing for each hole. Partially cover one side with Extruded Butyl Rope. Press the 2 sides together with the butyl at the center. Put the sandwich on some aluminum foil and put it in a 250F oven for 30 minutes. Take it out and go over it with a roller. This flattens the butyl and spreads it over the entire surface.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/flashing_sandwich.jpg

 



Whatever you make the covers out of, run a bead of Exruded Butyl Rope around the mounting surface before pressing them in place. This will improve the seal and will add more vibration damping to the door. Hold in place with self tapping screws or a fastener of your choice. Remember that doors are exposed to water. If you drill pilot holes for your fasteners, priming and painting them is a good idea. I use a good coating of Loctite too.

Next up - applying the mass loaded vinyl and closed cell foam.

Door Kit - Part 3

Now we're ready to fit the mass loaded vinyl (MLV) to the interior door skin. The goal is to cover as much of the door as we can and still get the trim panel back on. Any holes we make in the MLV to fit wires and for the door open cable to pass through should be as small as possible. If we make a mistake, it can be repaired using HH-66 Vinyl Cement.

First hang the MLV using Velcro patches. The patches are large enough and strong enough that you should cut them in half for easier positioning. Peel the release film off of one side of the Velcro and press it onto the door along the top edge where you will be mounting the MLV. Repeat so that you have two mounting points. Peel the release film off of the 2 Velcro pieces mounted to the door. Align the MLV and press into place. To assure that the Velcro adhesive is firmly affixed, Peel the MLV off the door, separating the hook and loop sides of the Velcro. Press down the sides mounted to the door and the sides mounted on the MLV.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/mlv_01.jpg

 



This shows the positions of the Velcro patches after the door is complete. At this point just put 2 along the top and the one at the top right doesn't need to be a whole strip.

 


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/velcro.jpg

 



Trim the MLV to allow clearance for the clips.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/mlv_02.jpg

 



Pull the egg crate looking plastic piece off - it's just hot glued in place. Throw it away.
http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/egg_crate.jpg

 



Take note of the bracket and screw slots.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/screw_slots.jpg

 



Here you can see the cutout for the bracket and the hole I'll have to come back and fix.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/screw_slots2.jpg

 



Remove the MLV from the door and lay it inside the trim panel for fine tuning. There's a lot of information in this photo.
1) I cut the MLV to allow the bracket in the last photo to just fit through. I then covered the hole with a scrap of 1/4" CCF using HH-66 Vinyl Cement. This way, when you screw the trim panel back down you will still have a tight seal and the CCF will eliminate any possibility of rattling.

2) This was a mistake I made and repaired with a scrap of MLV using HH-66. When I had the MLV mounted to the door I cut the MLV to match the hole behind the handle. Not necessary - plenty of clearance without cutting the MLV. HH-66 creates a bond that is stronger than the vinyl itself. No harm no foul.

3) The MLV overlaps the black styrofoam inside the trim panel. This will make the trim panel impossible to get back on. You'll need to cut the styrofoam down 1/8". I used a sanding drum on a Dremel - zip zip, done.

Finally, notice the little extension pieces of MLV on the left side and the bottom. Again. MLV scraps and HH-66. May as well fill that panel as much as possible. Also notice the amount of clearance around the clips and alignment rods.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/mlv_04.jpg

 



Getting ready to wrap this up. Here you can see the error I made (and repaired)  and the extra holes for the lock knob, handle cable, etc. Make sure that the hole you cut for the lock knob rob has enough clearance for both locked and unlocked positions. I cut the MLV so that it exactly fit the speaker opening so that the speaker goes back on top of the MLV. I've also added 1/4" CCF to the surface of the MLV using HH-66. You want to add as much as will fit.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/doors/mlv_05.jpg

 

Reassemble door. Done.

 

Floor Kit
First things first. If you are going to do the Floor Kit you really ought to do the back wall kit too and at the same time. You need to remove the back wall to do the floor and the two areas sort of run together.

Remove the negative battery terminal.

Slide the seat forward and move the seat back forward to give yourself some space. Remove the nuts holding the seat down. Unscrew the black plastic carpet hold down. It has an Allen wrench fitting but you can unscrew it by hand.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/seats_01.jpg

 

Slide the seat back and remove the front nuts. Tip the seat back and disconnect the wire harness connector(s). Lift the seat out of the car. Remove the other seat. Pop the door sills off.

Remove the back wall side trim pieces. Remove the speaker connector.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/side_trim.jpg

 

Pop of the center console/hump trim. Pop off the back wall trim.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/back_wall_trim.jpg

 



http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/trim_removed.jpg


Remove the dead pedal and remove the carpet from both sides. You should be looking at this.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/carpet_removed.jpg

 



Next - to scrape or not

Floor Kit - Part 2
Here we are. Notice the box bolted to the passenger side floor. Remove the nuts that hold it down and remember its orientation. We're going to cut the CCF and MLV so that it still makes contact with the floor when we put it back.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/carpet_removed.jpg

 

This where you decide which Floor Kit you will be buying based on whether or not you want to scrape out the factory vibration damping on the floor. It looks OK in this picture but it had lifted up from the floor in a few places and had never been bonded to the floor in others. Air space between a vibration damper and the substrate renders the vibration damper completely worthless.

I was pretty disappointed to run into this stuff in this car. It's asphalt with some sort of metallic/metalized coating on top. Right next to it there is a very high quality material used on the center hump. For whatever reason they cheaped out big time on the floor. I won't go into all of the reasons why asphalt is a very poor vibration damper and why it shouldn't be considered a permanent material for use in motor vehicles.

The fact is, if yours is in reasonable shape, there will only be a small improvement in noise reduction if you take it out. We're going to go over this surface with CCF and MLV anyway and that will account for most of the noise attenuation. Whether you leave it or take it out is going to be more a function of the kind of person you are. If trading 2 hours of your life seems absolutely worth it to know that you have done everything possible or if you want to know that the vibration damper on the floor won't be causing any problems in 20 years, take it out. You know who you are SmileIf you are going to leave it in there, go ahead and skip to the next section.

Now that the slackers are gone we can get down to business winkThe good news for those of you who will be removing the asphalt is that asphalt melts at 180F. That's bad for durability but means you can scrape most of it out with a heat gun and a putty knife. Being careful not cut into the e-coat, warm an edge of the asphalt, slip the putty knife under it and work your way across.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/asphalt_01.jpg


Once you've gotten everything up you can by heating and scraping, use a shop vac to get up all of the brown grit you couldn't pick up by hand.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/asphalt_02.jpg

 

Now it's time to add some mineral spirits. You'll also need some rags or paper towels. Pour an ounce or so of mineral spirits onto an area with residue remaining. Spread it out with your putty knife and let it set for a minute or so. Use the putty knife to gently scrape the residue away. Use a rag to wipe up the glop. When you're done, Put some mineral spirits on a rag and wipe the surface down. Finish up with a denatured alcohol wipe down to get rid of any oily residue. Now you have a nice clean floor. You get points for dedication. If you want points for being a hard-ass, use an acetylene torch like Bobby did on his side.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/no_asphalt.jpg

 

Next - applying CLD Tiles to the floor.

Floor Kit - part 3 We start installing stuff!

If you left the stock vibration damper in place, your best bet is to apply the 6 CLD Tiles in your kit to the untreated portions of the floor. There isn't much to be gained by applying them on top of the existing material.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/cld_tiles_with_stock.jpg


If you took your floor down to the e-coat, something like this is the way to go. The brown stuff you see isn't rust. It's asphalt dust that stuck to the joint caulk because we didn't have a shop vac to suck it up. Won't hurt anything.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/cld_tiles.jpg


Everybody's the same from here on out. Lay one of the CCF sheets on the floor and trim it to just cover the horizontal surface. Here you can see the cut-out for the block that bolts to the floor.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/ccf.jpg

 

Lay the MLV on the floor. You want it to run up the door sill a little bit, up the firewall/foot well as far as it will reach and as far up the center hump as it will reach. Press down on the MLV above the threaded studs and they will break through. Make sure to get them all. You will have to cut slits to get around the corners. Do it in a way that the resulting flaps overlap.


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/mlv1.jpg

 


http://www.sounddeadenershowdown.com/images/vehicles/kappa_kit/floor/mlv2.jpg

 

 You could put everything back together now, but since we've already agreed that you will do the floor and the back wall at the same time, I'll move on to the back wall next.

 

Back Wall:

The following pictures are from JohnyMac and can be found on the Kappa performance forum

http://kappaperformance.com/index.php?topic=1887.20


Place the CLD tiles on the back wall as shown in the following pictures:





 

Trim the MLV Material to fit the rear wall. You will need to remove all of the electrical components off the rear wall so you can install the MLV Material.

 

 

After the MLV Material is attached to the rear wall, Re attach and re-anchor all of the electrical components and wires as before.

Re-install the Monsoon system if applicable.

 

Remove the XM radio unit on the floor and install MLV material under the XM radio base. Use enough material to fold down over the center hump.

 

Trunk:

The following pictures are from Bryan's install as documented by DeepBlueGXP in the kappaperformance forum:

 

http://kappaperformance.com/index.php?topic=2450.60

Remove the trunk carpeting and place CLD Tiles in trunk as show

 

Trim foam material to lie on trunk floor and "alter" as shown below..

 

 

Trim MLV material to fit on trunk floor and on top of the "alter". When done, reinstall the carpeting material.