This is my first topic here at clubwrx and first how-to anywhere.
Please don't be too harsh on the flaming.
After a bunch of researching here on the forum I could not find a similar topic.
THE FOLLOWING PART IS NOT RELEVANT TO THE BUILD. FEEL FREE TO SKIP IT!
I'm going to start with a little history on the project. I wanted to put a sub in my car for a little bit better quality of the sound. A while ago I installed a 10'' Alpine Type R in a regular sub woofer enclosure. However after I had to move about 800 miles, I realized that a huge amount of the trunk space is completely useless because of the sub woofer. Even though it was all the way in the back (of the car) it did not allow me to put massive items (like suitcases) in the trunk. I could only fit one where now I can fit two.
A couple of weeks back I decided it's time for a change so I went ahead and bought some fiberglass and resin.
THIS IS WHERE THE HOW-TO STARTS
What you will need is some fiber glass that can be bought from any hardware store. I purchased about 3 sq. m. which is about 32 sq. ft. I bought the Fiberglass cloth and not the fiberglass mat. The cloth is easier to work with.
It looks like this:
I bought mine from Canadian Tire but I've seen it in AutoZone and in Menards as well.
You will also need fiber glass resin and hardener for it. It is usually sold in one package with the resin but check before you walk out of the store.
I had to put about 10 drops of hardener for every 1 oz. of resin. For you it might be different. Read the instructions.
I also needed brushes... lots of them... I used 4 or 5. I went ahead and bought a package of 12 for $3 from the local dollar store. You will be throwing them away after every use.
Also get some sandpaper, a grinding machine of some sort (I used an angle die grinder) and a marker, some cardboard and a piece of plywood about 2x1.5 ft. You will be cutting this out. I stopped by my local music shop and bough black mat (the one that looks like the trunk) and a quick connection piece for the sub enclosure. If it is unclear what I am talking about there are pictures bellow, you will need tin foil and masking tape.
To get started I took out the trunk mat and took out the side liner from the left side of the trunk. You can use the right side too, I just had my wires running there already.
Next, I noticed there is a hollow space behind the liner. So I cut a big hole in it. This way I have more space for the sub. 10" speaker requires about 1 sq.ft. box.
Once you take that side liner off, you will see a black wire behind it. You can easily take that and push it further back or into the side of the car so it gets out of the way. Just make sure you don't cut it or pinch it somewhere.
With that done, I re-installed the side piece back on.
Now you will need to make the molding for the back of the enclosure.
I shoved some towels and rugs in between the quarter panel and the inside of the car (where that pink towel is showing up). The reason for that is that you will need something there to be able to press with the brush. hen I used a ton of duct tape to connect the black side piece to the trunk. That green masking tape is as far out as I went with the fiber glass at this stage.
Next, you take the tin foil and the masking tape and you go crazy on it. Every single sq. inch needs to have either tin foil. It does not let the resin through. Resin does soak in the masking tape though so be careful.
Your end product at this point should look something like this:
Now you have to take the fiberglass and the resin and put 2 or 3 layers. Remember, this is just the back molding it is not finished product. You can add more layers to it after it dries and you take it out of the car. (I added 2 more for a total of 4)
Once it has dried you can take it out of the car. Do not forget to remove the duct tape and the towels/rugs from the back. This is what it should look like
For the front, I used some sort of ply wood. Not sure of the exact name but any plywood would work.
Take the cardboard and shape it in the shape in which you want your subwoofer face to be. I wanted mine to be flush with the inside of the quarter panel. (check the final picture to see exactly what I mean). Once the cardboard is shaped, outline it on the wood piece and cut it out.
To attach it to the fiberglass back:
Put the fiberglass piece back in the car. Make sure it fits. Take the wood piece and put it where it is supposed to be after you are done. Mark 3 or 4 spots on the fiber glass and measure the space from those points to the front piece. Use some 1''x1'' wood pieces to cut them out in those measurements. Once that is done attach them to both the fiberglass and the wooden panel you cut out.:
This is what it looks like from the side:
It looks like I can only attach 10 images per post so I will reply to this topic with the rest pretty soon. I will try to get the rest tonight.