[jesseunvoas]

DIY FiberGlass boxes (many pics)
This is a older one of mine but maybe your guys could use the same technic for bike parts or shoud i say (CF parts )

I got all my supplies through work you might also be able to get everything at walmart or a home depot I will list of what i can remember that i needed:

make sure if you do use these that they are crappy since if the resin gets on it say goodbye to it and don't touch the resin with your hands this shit is nasty and is sooooo hard to get off but the fumes are GREAT!!!!

-fiberglass mat
-resin/hardener
-tape different sizes
-latex gloves
-respurator good one (trust me)
-pan (to lay the resin in)
-paint brush
-scizzors/exacto blade
-dremel or other rotary cutter
-safety glasses
-heat lamp if it is cold out side
-crappy clothes (this stuff will ruin your cloths)
-glue gun/glue sticks (many)
-dowels
-cloth (larger lenghts) cotton or some old bed sheets
-saw
-sand paper
-bondo or putty (fiberglass filler)

make sure to do it outside cuz it will be really strong when you lay it.

First off we need to tape off the side you wanna do or both(thats what i'm doing)

now that you have that done you wanna lay tin foil down so that the resis does not stick to the carpet;

i marked off the portion with tape that i will use as the box but it is a good idea to lay fiberglass over the line.

try not to let it some in your house while it's a bit wet my Cat in the pic got all messed up for a day.

here are pics of after i pried the 1st and 2nd layers out now you will see that there is still some tape and tin foil on now i sujest getting most of it off try sand paper or a high pressure blow gun

Now these pieces of wood are used for the rings in the box they are 15 by 15 pieces of 1/2 MDF you can use larger if you want but 1/2 worked perfectly for me.
I used a ruller with the hole in the so i could mark a perfect circle and carved a groove in the ruller where half of the 12 inches are and the inner circle is the depth of the sub that would lay on but you could figure out the dimension here a pic that i used but just went for 12 inch subs

heres pics of the rings after i cut them i just used the dremel and some different bits to get the job done

 

[jesseunvoas]

just keep test fitting them till they go in the subs base

shit that were my wrench went hell of a time changing the bits in the dremel lol. I cut a bit too much where the black marks are just make sure if this does happen to place this in between the holes so you dont put a screw through that part also mount this the proper way when mounting it onto the box.

next step glue the dowels into the box to mount the ring just make sure to glue the shit out of it si it wont move when you mount it

now that you have it glued on just test fit them in

there lots of clearance also mount the ring to point what ever way you want it i have mine pointing somewhat to the front of the car at an angle

now that cloth i listed you just glue it to form to the box how you want i also glue it to the ring so it molded that as well cut the excess

now next step is to go back outside and pop a whole shit load of resin over this bad boy and lay a layer of fiberglass matting on and let it sit a couple of hours

use the dremel to cut the excess off and lay nore layers as needed

I forgot also to mension that i layed 5 layers of mat on the 1st shell but it may vary just keep checking it and when the flex is gone or you think it is strong enough then you can move to the next step.
Im not done on this final part im only on the 1st layer here and i will take me 2 more days I lay 2 layers at a time after thats all done im gonna pop on some bondo to smooth it off then after that im gonna carpet it

feel free to pm me if i left something out that you know of

 

[jesseunvoas]

UPDATE:

well last time i posted pics on this thread i had just fiberglassed the last layer of matting and now in gonna toss some more pics out your way!

here i had cut out the opening:

here i test fited a tad bit tight so i just sanded and little bit off in some places:

that green crap is long strand fiberglass i placed it on all the crack on the inside and some weak spots on the outside just for good measure:

now i fishished off with some body filler:
I also test fit it in the box as well, fits like a charm

here i put in in the car for the first time and it looks awesome!!!!

now i post pics of some of the stuff i used as well:

AND FINISHED PICS

here now i finally took pics of one done and with carpet laid:

Now all i need to do is get some industrial strengh velcro and fasten that from the back of the box to the trunk liner now.
good luck everyone,
JESSE

 

[jesseunvoas]

some things i would like to add is dont be ratarded and get a cheap mask this stuff will kill you the fumes burn soo bad even get some safety glasses and wash the resin off as soon as you can i got a rash from it and yes the resin not some hobag i picked up at burger king

maybe you guys can use this DIY for you bikes i know i am gonna do the same technic for a header shroud

 

[skr00zloose]

i used to do alot of that stuff too. i don't use cloth like that though, i use a polyester mat that you can get at any arts and crafts store. it's a lil thicker, soaks the resin better, and when it's dried, seems to handle the stress of the subs better.

you can make custom door panel and kick panel pods in much the same way to get better aim of your front and rear fill speakers.

looks good man, especially after it's covered, really blends in with the trunk. i wish i had pics of my old civic with 4 10" subs mounted in a f/g box built under a false floor in the trunk. with the acustically transparent material over it all, you couldn't see any of it, but you could damn sure hear it!

 

[jesseunvoas]

yeah i forgot to add i've moved onto different fabrics

 

[skr00zloose]

btw, nice socks.

 

[The Green Lantern]

btw, nice socks.

:Stupid: :LolLolLolLol:
good job on the tutorial dude

 

[ab420]

Great tutorial man, and it came out really nice too, good work!

 

[jesseunvoas]

yeah the other one is alomost done and i just used iundustrial grade velcro to attach it to my truck looks completly stock and pounds amazingly

 

[drunkNun]

What the fuck did u slaughter on the work bench? I used this same method in my old 96 civic hatch only i had 4 subs. the back seat out and 2 subs on each side pointing towards the hatch. I miss that car and all the car shows sometimes....had a built n/a b18c5(type r if u dunno) motor in it. That was the good ole days...

 

[sanitys]

looks like everyone uses the same methods. I always like to use that cloth before i start laying mat down. Just seems to make whatever part your making heavier. Last thing i made i just used an old t-shirt and layed some cloth on top.

 

[jesseunvoas]

yeah we had some premium fleece rags at the shop and thats what i used just cut the seams out

 

[drunkNun]

fleece works better than anything. And it makes for a better sound. When i used to make my fiberglass boxes i put a layer of Dynamat on the inside of them....but then again i was sponsored by dynamat. But it does sound alot better than just fiberglass.

 

[jesseunvoas]

well trust me i just was afraid my subs were gonna blow the boxes apart thats all