New subwoofer enclosure!

[skid_mark_steve]

Alright I could have done this in the D.I.Y section but it works for any car. By no means am I a master at this but anyone with any skill can do it. For more local advice in CT ask Demonfire or Zazza. I put up a pic of what my trunk looked like before for reference. I am changing it so the rest of the upgraded suspension will fit. Before the strut bar couldn't be installed because it would hit the box!

I made a ase template out of 1/2 inch MDF. then cut the rings and used 1/2inch dowels to build the skeleton. Then I stretched spandex (swimsuit thickness from a fabric store, fleece works better but it's summer and they were out.) and stapled it to the bottom edge to get my shape. Next mix the resin and double the amount of hardener and put it over the spandex. I doubled the hardener so it would dry faster and not take too long. The wet spandex might sag if it takes to long to dry. I now had a hard thin shape of the enclosure. Next take a sander or dremel or whatever and rough up the shell. Also cut out any folds that you had to do to get the cloth tight. It doesn't matter if your cutting out chunks. The shell is just for the basic shap not really for strength. Then lay down your first layer of fiber glass cloth. Use the normal amount of hardener (you may have to adjust it because of weather and humidity and such). Cut the cloth in to strips and lay it down so they overlap alittle, making sure that your getting it to the ring and the baseplate. You don't have to cover the ring, just get it to it. Once dry rough that up and do the same thing with the fiberglass mat (it's thicker). Then repeat again with another layer of cloth. Finally bondo and sand. You can carpet them (easier with less time sanding the bondo) or paint them (takes a long time to prep the surface smooth enough for paint. Right now I just finished the 1st layer of fiberglass cloth. I will have more picks once I get the rest of the layers done and everything installed. The old setup weighed 178.9 pounds. I pulled a NASA_tuner and weighed everything (including screws) when I pulled it.

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[drinkingmymilk]

looks good, i realy want to try glassing a box, but im to afraid.

[demonfire]

Steve, congrats! did you break your fiberglass cherry with that one? if so, NICE WORK!

couple words of advice -


1. what finishes the look nicely is a double top ring so the sub sits slightly recessed, what finishes THAT even more is to roundover the inner lip.

2. when you glass to the ring you dont need to go up top (only glass to the sides, basically). for extra strength when you're done fill the inner lip (where the glass meets the wood) on the inside with resin and some frayed chopped mat.

how many layers did you use? i generally go 5-7 with chopped mat. also, i use armor all buffing cloth to stretch instead of fleece normally. it's fantastic and doesn't soak that much resin like fleece does, and stretches better than fleece (and is cheap)

edit - i dont see a respirator on you... or gloves! wtf? how do you not wear gloves?

(gojo removes resin from skin, btw)

looks good, i realy want to try glassing a box, but im to afraid.


nothing to be afraid of. it's fairly simple, just follow the steps and dont rush yourself.

[Albysure]

that came out fantastic! looks real good. now...when you put the glass on that spandex did it stretch at all? and one suggestion. i see your amp kinda has a gap around the egde. can you put some kind of spacer under it to make the top just poke through a little? tighten it up. but anyway it came out great and i give you a big pat on the back for even trying to get that shape to come out straight.

[SOUTHPAW]

Noice Steve! The subs are gonna bump in those enclosures, they look kinda like my old ones... :cool:

[PicknCrew]

Unbelieveable....came out nice Steve! luxhello1

[skid_mark_steve]

Its not done yet! the top pick is what was in the car. I am taking out 2 of the 10's so I can install a strut tower bar. I only have 2 coats of mat right now. doing 2 more then another layer of cloth. It's really in the begginning phase and looks real rough. I am adding a ring over the subs when I install them but don't know what you mean by rounding the inner lip? Do you mean router the inner edge where the sub basket goes in or the outerlip of the enclosure? The ring is rounded and the bas of the enclosure is too. The center section that has the walls and the unglassed flat spot will house the amp and capacitor. It will have a cover over it like the previous install.

[jrave]

looks nice man!

[mattsPOStruck]

looks good dude....

you ready to help me with glassin the headliner?????

[skid_mark_steve]

you pick one up yet to cover in glass? Anytime.

[skid_mark_steve]

Well its all built. Now I have to wait for the subs. The place I bought them from was getting the shipment last week and now the truck has disapeared with 15K of there pre paid merchendise. You can see where the subs go, and the Orion HCCA 250 goes on the flat panel. Other things you cant see: upgraded from 4 gauge to 0 gauge for the ground to the capacitor and installed 100 breaker in the trunk so I can pull everything out with a phillips head and 8mm hex in about 10 minutes. Perfect for auto-X. I took out 178.6 pound with the old setup. this with out subs weighs in at a feathery 28 pounds. the subs are a 10.3 pounds each (I will verify when I get them) So I saved a total of 130 pounds (roughly) and the ability to take ot out if need be. (as you can see before there was no chance in hell to do that quickly, just ask Joe about that one).

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[2oooRT]

looks good, I dont have the patience for that stuff

[Neonchik01]

damn Steve it looks pretty good...cant wait to see it with the subs in there

[Juice33]

Looks pretty friggin good dude. Excellent craftsmanship from what I can see right now.

[Zazza CEO]

looks awesome steve, glad you didnt electricute yourself taking the capacitor out lol. and sounds like it'll be ALOT easier taking the stuff out, even if it isn't 2am before a show! good job man!

[skid_mark_steve]

Now another project. Same subwoofers in a Lexus GS 300. Have the first shell drying now. Little bit heavier, Kamakazi and I should start a business!
will have pics up shortly.

[skid_mark_steve]

and here are the pic's
http://www.tunernetwork.com/forum/gallery/data/523/medium/DSCN0630.JPG
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[belward]

sick i love fiberglass enclosures i know it can be a pain in the ass to work with...great job

[EdrikLongtail]

look awsome man

[ben_dover]

Nice job Stevie. The only thing I like about glassin' is getting high. Hats off to ya.

If the Kappa's disappear, I'll fucking kill you.

[skid_mark_steve]

All done, subs came in today, also got a fancy dead pedal. Here are more pic's of the Lexus box too.
http://www.tunernetwork.com/forum/gallery/data/524/medium/DSCN0631.JPG
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[belward]

thats a awesome jobby steve..and i must say that you have A sick rare amp..i only wish i coulda had a orion amp to go with my orion hcca when i had it
theres is nothing sexier than a clean install