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Hi this diy will explain step to step how to do a custom subwoofer fiberglass box.

First before doing anything always put a ventilated mask cause fiberglass can do perm damage to the brain. Be smart and protect yourself

First what you need for that project is

Ventilated mask
Fiberglass resin at least 1 gallon
Harderner mekp
Fiberglass chopmat and/or weave
brush(es)
masking tape
aluminium foil
plastic glove
mesuring cup / pale
Acetone
fabric
mdf 1/2
BEER

First you need to spot where you wanna put your sub woofer.After that recover the whole part with masking tape. Its will look like this



after you recover the masking tape with the aluminium foil to protect the trunk in case fiberglass stick to the carpet.



Now its time to begin to make the first layer of resin of fiberglass. Put your mask and plastic glove.Mesure 2 oz of fiberglass resin and add 20 drop of harderner in a bowl mix up and apply on the aluminium foil then add the chopmat or cloth fiber until it become invisible. You must to work faster cause its stick fast. After you are mixting another batch of resin put your brush into a bowl of acetone so your brush will not stick. After you did your first layer wait until is dry to the touch.When its dry remove the fist layer in your trunk and you can work on it away from the trunk.



Remove all tape and aluminium foil as you can



Now its time to add layer to the mold so if you work with chop mat add about 6 layer and wait until its dry.



If after 6 layer is enough strong you can stop adding layer if not add layer until your mold is strong enough to climb on.



Now its time to remove over stock and give the final shape to your mold into the trunk with a dremel or electric saw just draw the shape you need in your trunk and cut it.



Now its time to make the ring for your sub woofer



you need to obtain some data

So edge to edge of sub is 10" (but i have 12")
distance from edge of speaker to mounting edge .375"
So edge to edge of sub - distance from edge of speaker to mounting edge = 9.25"



Now you need to make 2 ring in the mdf

so the diameter will be 11" for the 2 rings.
With a rules stick a nail in the hole and make 1 circle at 11" and another one of 10"

Make another 11" and 9,25"

you will get 2 circle 1 bigger than the other one.

Glue those togetter and wait tomorrow until its dry and put some weigth on for the white glue make is job.

you will get this



Now is time to mount the ring into the mold. With a glue gun glue some stick into the ring and to the mold be sure its strong enough. Warning check the sub woofer spec be sure you have the right volume for your sub cause it will sound bad.





and watch into your trunk if nothing will hit the structure



Now its time to put fabric on the mold with the glue gun. Strench the fabric to avoid some bump.



now put some fiberglass resin on the fabricand wait until its dry.
Add some layer about 6 layer and wait until its dry.



cut the over stock with a metal saw



reinforce the edge outside and inside the mold.



when its dry sand the mold until is soft and test the mold into the trunk



you can add connector the the mold





Now its time to test if the sub woofer fit into the mold



now you can add fabric or paint it.

I will show you the difference between the mdf subwoofer box and the fiberglass









There you go enjoy

For any information you can email me at koston78@hotmail.com