Nice! Just so everyone else knows they sell these already made and painted or non painted at www.bavauto.com. Just search subwoofers (Cannot provide a direct link Bav Auto wont let me). I am going to be getting one mostly likely.

 

I had to work this friday, saturday, and i went to the red bull drift event in long beach. Got to take home some takeoffs as souvenirs. I need to find a marine supply store to find some PVA. It will be done before the PCH cruise. The Bav auto enclosure is a pretty decent looking enclosure but i'm not a fan of 10" woofers.










Bavauto's box

 

So after making several trips to paint supply stores, an ebay + google search lead me to the west coast distributor for one of the nations largest composites supply companies. And the best part is is i get the stuff for the same price as retailer. No business license, no membership cost, no minimum orders. So i got my PVA and some honey wax for about half of what i was expecting to pay. Unfortunately they only sell fiberglass in 100 yard rolls but they referred me to one of their retail customers. I picked up 3 different styles of glass along with some sweet tools of the trade. My Dremell came up missing so I bought a Ryobi cordless speed saw and an angle grinder. So 3 days and $200 later i can finally move forward. I started with sanding and grinding the mold and filling in major imperfections with Evercoat glaze. I then applied 2 layers of honeywax and 2 thick layers of PVA. I started applying the resin doing a third of the mold at a time since the contours made it hard for the fiberglass cloth to hold its shape. I ran out of sunlight so i'll finish glassing it tomorrow and pull it from the mold.

 

can't wait to see the finished product!

 

So i finished glassing this morning and pulled the part. As i expected my crappy mold was not smoth enough for a clean pull so i had to destroy the mold to safely remove the part. It needs alot of filling and sanding to make it worthy of making a master mold from it. I might just drop it off at the bodyshop and let them deal with it.

 

I had a little free time on my hands today so i got started on the back of the enclosure. I laid out and taped some thin plastic painters "drop cloth". The best thing about this stuff is the the fiberglass resin will not stick to it. It just pulls tight off the finished product. As always it will need some work before i can glass the two sections together.

 

man the suspense is killin me!

 

I have done quite a few boxes like this. If it helps here are some pics for you guys to check out. By the way, in terms of acoustics, the corner is a good place for the subwoofer since it reduces cancelation that occurs in most installs that just have a box set down in the trunk somewhere.

 

Its done. Finally. Just need to wire it up and i'm set. But all of a sudden i can't find my hi level input cable.

 

Here are the final pictures of the install. All in all it was a great learning experience. I made just about every mistake possible and it still came out ok. If i were to do it again i would have just modified the existing panel. It was not worth the extra time, energy, and money to create an entirely new panel. At least not for someone with lack of experience.