[ Sub Install ] (Part 2)

Need

* 8 Liters Polyester Fiberglass Resin
* 15 meters Fiberglass Mat
* Additional Resin Hardener
* Dremel / Rotozip / Cutter
* A GOOD Respirator
* Angle grinder
* Disposable Paintbrushes Brushes
* Masking Tape
* Tin Foil
* Glue Gun, or Adhesive Spray
* Fleece Fabric
* Wooden Dowels
* Carpeting Material
* Packing Peanuts
* Wiring Materials
* Light Sandpaper
* Patience

For this I followed the instructions that are found HERE
Because all the info is here I will not be very detailed but will show my progress.

Step 1: Create the backing shell

I originally got a fiberglassing kit from Bunnings for $50. I thought that would do a couple layers and at least do 50% of it… WOW was I wrong. I have never done fiberglassing before and didn’t realise how expensive it was.
After I used up all my original kit I had to think BIG. Found a seller on ebay who was selling lots of it for good prices.. (I assume it is good as it tones cheaper than the Bunnings idea)

I hope 20 meters of mat and 4KG of resin will be enough for this..

While I wait till that arrives I started with my first layer.

After it dried I noticed a lot of little air bubbles.. I didn’t notice this while layering. I hope they can be sanded out.

Found out that sanding fibreglass isn’t the best idea. You need something a little more aggressive called an angle grinder. Fixes those bubbles quick smart.
A couple more layers before I take it out of the car looks like this.

I have no idea how many layers are on this. I am using 600gm mat which is thicker than the normal 450gm.
I think there are about 5 layers on there. It is very strong and Im nearly out of the 4L resin so I guess it is time to stop.

Step 2: Create a bracket for the speaker

For this I found some old MDF lying around. I wanted the sunken look to the speaker so I made 2 rings. One is for the speaker to screw onto and one is for the outer shell.
After I made the two rings using I wood glued them together then put in a couple nails just to make sure.
I got some dowel that I was going to use to hold the ring in place however it did not quite work and I had to end up cutting some mode MDF to make stronger rods.
This was then hot glued to the shell.

Step 3: The top shell

Find some material lying around at home. I got some bright material so I could see the mat easier.
Stretch the fabric and hot glue to side.

I found a local dealer of fibreglass goods. Go see “Fibreglass Material Services Pty. Ltd.” In Seven Hills (02) 9624 2811
I needed this as I ran out of resin again..
Coat the fabric in resin.

Do 5 layers on the top making sure that you go around the edges.

Here it is installed

Step 4: Finishing touches

I got some putty and tried to make the surface smooth. Not sure if it was worth it or not..

Now to install the carpet.
I made some little G T I wooden pieces. The plan was to add embossing under the carpet. However the box is small and it didn’t look right so I decided to ditch it.
Shop around. I got quoted from $18 to $50 per meter. (Most expensive was a carpet wholesaler.. go figure.)

Get yourself some spray on adhesive. Start at one corner and slowly move around the box.

Then Install. Done

Costings

Bunnings (1m mat and resin, respirator, paint brushes, gloves, plastic sheet) = $90
EBay (15m mat and 4L resin) = $200
Corner store (plastic containers, gloves) = $10
Fiberglas Place (4L resin) = $68
Carpet = $18

= $386

Added some embossing with new Sub and Amp

Here other peoples projects where ideas came from:
* Clean Look
* Nice
* Sweet Embossing