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| Building a Fiberglass Subwoofer Box |
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The purpose of this tutorial is to show you how to work with fiberglass to make a subwoofer box located in your trunk behind your wheel wells. Although this tutorial is made to go into your wheel well areas, you could use this tutorial for anything, kick panels, racks, and other speaker boxes. If you have some knowledge of working with fiberglass, then this should be a walk in the park. (I suggest reading the sound deadener tutorial before you do the fiberglass boxes, it will limit vibrations from your subs hitting hard.)
Materials/Parts:
-1 Gallon Polyester Fiberglass Resin
-Fiberglass Matte
-Additional Resin Hardener
-MDF (For supports, and speaker rings)
-Dremel / Rotozip / Cutter
-A GOOD Respirator
-Disposable Paintbrushes Brushes
-Masking Tape
-Tin Foil
-Glue Gun, or Adhesive Spray
-Fleece Fabric
-Wooden Dowels
-Carpeting Material
-Packing Peanuts
-Wiring Materials
-Light Sandpaper |
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Additional Information
This project will not be easy, it will require about 30 hours of work, drying, and adjustment time. Expect at least 8 hours of working on the first day to get your car in order, and get a good pull of your trunk space. In the end you should have a show winning sound set up that will look as good as it will sound.
1. Remove Everything From Trunk
You are now going to need to remove as much as you can from the trunk, everything you may have in there that will get in the way should be removed, even the trunk lid if it gets in your way. The carpet should remain, and you will need to get it as smooth and as perfect to the contours of your car as possible. Use a Vacuum to suck up any debris and dirt that will be in your trunk, you don't want to be dirtying up your box.
2. Tape Layer
 Using a good quality masking tape, the blue painters tape works best, start creating a layer of tape in the area that you will be glassing. I recommend that you do 2 layers, and crisscross them to ensure you don't get resin seeping through. Resin will not come off of metal, clothes, carpet, or your dog, so be careful. Extend the tape layer a few (3-4) inches past where your box will go, and also glass out a few inches past that (but within the tapes area).
3. Tin Foil Layer
I have seen some tutorials do this, and some not, it is really up to you. it is an added layer of protection from the resin seeping though to your carpet, and I highly suggest it. Use squares of the foil, taping and overlapping them as you go. You should now be ready to start the glassing.
Protecting the interior is very important as this stuff will not come off. I suggest placing newspaper, or drop plastic all around your work area. Also, if you like you can also put a sheet of plastic between your trunk and cabin to prevent fumes from getting in and stinking up the car for a few days.
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