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Old 05-08-2011, 10:07 PM
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Default How to: Custom Fiberglass Enclosure IMG Heavy

Here are pictures of how to make a corner trunk box.

Tape up area, multiple layers of painters tape in opposite directions (IE horizontal, then vertical).





Cover anything that you do not want to ruin with plastic.





Spray the tape down with PAM cooking spray, or wipe it down with mold release wax. Pam is cheaper and more accessible.

Shred your mat (really curvy 3/4 oz, flat area's 1.5 oz.) into small pieces. Rip it apart, do not cut it up 4"x4" or smaller pieces.

Mix up your resin and lay 3-4 layers of glass and resin down.





Go to bed, it's been a long day. - let sit for 12 hours or so. putting the glass out in the sun will speed up set/cure time.
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Old 05-08-2011, 10:11 PM
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Tuned into this one.
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Old 05-08-2011, 10:16 PM
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Day 2 - Remove the "plug" from your trunk

You should have something similar to this.







Once it has cured and is no longer "tacky" put it back on the bench and layer up several more layers of mat. Number of layers needed will depend on how much of the area is flat vs curved. Curves are stronger and do not have to be as thick as flat areas. You do not want the enclosure to flex.





Get out the dremel and start trimming / sanding on your box, shaping it.





At this point you mainly want to trim off the rough edges and roughly trim the shape you want. Then you will want to test fit the enclosure back into the car (make sure you didn't shrink it while adding more layers) and mark it with a marker to give you some better guide lines to trim it down to.





Proceed to trim and sand some more. In my case I made a speaker terminal into a large flat area of my enclosure to stiffen it up and to add a custom touch.









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Old 05-08-2011, 10:21 PM
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nice, subscribed
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Old 05-08-2011, 10:26 PM
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Nice work man!
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Old 05-08-2011, 10:29 PM
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needed this thank you!
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Old 05-08-2011, 10:32 PM
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Okay honestly, I did not complete all of the above steps in a single day.
From here on work at your own speed, this has been a month long project for me and I am still not 100% complete with it.

More sanding, I had about burned both brushes up in my dremel's motor.



Okay now to start making this thing into a recognizable shape - an enclosure.
Start with making a ring - a plunge router and a circle jig is highly recommend here
Dato the edge to staple the material too, and recess the subwoofer, it will look much cleaner in the final stages. In my enclosure it is 2 rings of 3/4" mdf.





Okay you then position the ring where you want it with some dowl rods. Using CA Glue - available at any good hobby shop - attach the ring to the back/bottom of the enclosure. Some activator will also aid to speed up this process. Sorry no pics of just this process - I was excited at this stage and forgot to stop and take pictures. You'll see what I'm talking about in a minute.

You can use fleece - choice for many years. I chose to use "ponte" it's a 100% polyester cloth. It is slightly thicker than speaker grill cloth and just as stretchy. Stretch your material snuggly over the ring and using the CA & Activator attach the material to the outter edges of the enclosure.

You should have something similar to this.











At this point you are going to need a stapler - I would suggest a pneumatic upholstery stapler. Shoot the cloth to the speaker rings dado edge. then trim the material from the center of the ring.



see the dowls?



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Old 05-08-2011, 10:39 PM
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MORE!!!!!!!!!
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Old 05-08-2011, 10:43 PM
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Okay tape off your ring on the inside and top edges to protect it from the resin you are about to add.





Okay mix up your resin and wet out the cloth.





Okay set it out in the sun. The UV rays help speed up the polyester resins cure time.





Okay at this point my original plans took a detour. Originally I had planned on laying up the layers of glass (for the front and top) on the inside of the enclosure. I quickly found out this was going to be impossible through the 9" speaker ring - for a 10" JL subwoofer. So I had to lay my glass up on the exterior.





I did manage to get one of the interior seams the way I had originally planned...



The other three I had to "milkshake" them. This is inside the box.





Okay back to the outside, more layers.



At this point you can sand down the edges, remove the dowls (hammer blows and they'll come out), and I would highly suggest test fitting the enclosure again. ---- let it cure before trimming, and definately before any test fitting.



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Old 05-08-2011, 10:56 PM
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For those wondering this the trunk of our 2004 Mazda RX8. This was also my first enclosure build of this type - fiberglass.

Okay now onto the fun stuff, body filler. I used Duraglas for this step. I highly suggest that you sand it during the "green stage", or it is extremely difficult to knock down after it's completely cured.

1st layer - missed the green stage - popeyed my sanding arm.









2nd layer







This is it for now. The enclosure is actually ready to be carpeted at this point. If I was going to paint it or use it as a plug for a mold then finer sanding and finishing would be in order. I will post pictures of the rest of this build as soon as I get the problems with the seller of the subwoofer I purchased straightened out. It should completed within a week, so stay tuned. Hope you have enjoyed up to this point.
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