What takes alot of time the curing of the fiberglass? The reason I am asking is because I plan on doing this as well for my GXP.

Let me get this straight you:

First molded the shape using aluminum foil then spraying it with the foam to keep the shape?
Then took out the whole mold and covered the outside with fiberglass.
Then tryed to get as much aluminum Foil out and the foam out and fiberglassed some more.

When does the supports come into play with that? I would suppose before the second glassing?

Hey! That'* sweet! Wanna come do mine?

Yeah, the longest parts are: the resin mix drying, and sanding the exterior after applying filler.

Yep, aluminum foil. You can skip the foam method since it'* plenty warm outside to lay glass. I did the foam so I could bring it inside, out of the cold, and work on it. If you do the foam method, pull it out, put 1 layer of glass on the outside, pull out the foam and aluminum, and lay the rest of the layers on the inside.

If you just do the aluminum foil with no foam, just lay all of your layers down over the foil. You can use caranuba wax between the foil and the fiberglass so it doesn't stick, but I never do.

I put the dowels in for strength, and not having to do as many layers. Rope works much better, as it will soak up the resin better than the wood will.

Trimmed away excess.

Used dowels to support my MDF speaker ring in place.

Wrapped in a fleece-like fabric. It feels a lot like fleece, and you will find it in the fabric section at Walmart with the fleece, but it'* super stretchy. Be sure to get out ALL of the wrinkle'* wherever it may be visible. If you do not, you will have TONS of fun trying to cover those later with filler. I also use 3M'* high strength spray glue (like $10-$20/can at Home Depot) to hold the fabric to the box.

After it is wrapped, put a layer of JUST resin into the fabric, no matting.

Now here'* another decision for you to make. If you can reach inside the box and lay the glass from outside-in, do it. It will make doing filler and sanding much easier later. But, if you don't think you can, lay the glass on the outside.

Once your totally done glass, sand it a bit with some rough paper, and start using filler to go to down. Rage Gold is recommended, I'm sure anyone on here that does bodywork knows why. Super easy to sand, works awesome. But... not cheap.

If you get it smooth enough, you can paint. If not, you can carpet it.


BTW, don't cheap out on materials. USC Composites or Evercoat resin works wonderful. Rage Gold for filler, hands down.

Buy plenty of 1" wide brush, cut the bristles to like a half inch stubble. Your just looking to push the resin into the mat, not soak it. Also having the stubble makes it stiff, easier to push out those pesky air bubbles.

Cover your work area! I cannot stress this enough! Wherever you drip the resin, it'* staying there!

Wear gloves! That stuff burns when on the skin! I'd recommend a breathing mask as well if you are working in a closed envirionment. If you have air circulating or are in an open garage, don't worry about it.

Be sure whatever container you choose to put your resin it, make sure it won't eat through. Plasic party cups are a fine example of a bad choice to hold the stuff. It will just eat right through. Paint trays work fine, especially the cheapy'* at Home Depot.

Umm..... I can't think of anything else now. I'm sure I will later. Hopefully this answers a lot of questions. I would also recommend checking out www.fiberglassforums.com if you are really interested. You would be suprised on the projects some of those guys turn out (custom Ipod docks for computer desks, complete vehicles, etc....).

Now thats what I was looking for, I am new to this. Thanks for the info!

No problem.

I never really read any type of a review of this enclosure. How did you like it? Like Vince asked, how hard was it hitting? Any noticeable rattles due to placement? I was wondering because I noticed you were selling it quickly after you built it and assumed you were dissatisfied.
Grant

Oh no, definately not dissatisfied. Actually... I traded off the JL for something different. I cycle through car audio like I change my underwear Obviously, it didn't hit as hard as the 2.6 ft^3 slot vented box tuned at 36hz did, but that box was built SPECIFICALLY for that sub. I actually started this box completely out of boredom, and then it quickly turned into an idea of having tons of trunk space while still having the sub. I actually did not even think of calculating the air space until I had actually wrapped the enclosure in fleece, and then I started worrying! But, all was well actually.

Lemme put it to you this way, with the slot vented box, I knew that it was probably around 140-ish db. This was with an spl specific song, going for all out loudness. Doing the exact same with the FB enclosure, I was probably only 3-4 db lower. Granted, this is noticable to the ear, but at that level, how much louder do you want it (unless you are competing)?

I had no different rattles with this enclosure than with any other enclosure. The taillamps can be pulled out easily enough to apply bits of weather stripping (it will absorb the movement between the taillamp and the metal of the vehicle).

DId you get rid of the box too?

Yep, sold it a few weeks ago. I have a pair of 10'* now, and it'* taking up my limited space here at college (at that time, the parted out Acura was still sitting in the garage as well). The new owner seems to be very happy with the enclosure, and is going to attempt to make a second one for the passenger side himself even! He got a great deal on it as well, considering I had about $80-$90 in materials, and I sold it for $40.


Lemme put it to you this way guys, I'll pop out a few more on my free time if anyone is interested. Obviously, this is no good for you pre-2000 owners, and it only works on Bonneville G-body'* (test fit in a 2001 Aurora, close but no cigar). The only problem is, free time is limited between 7-9 pm at night for the next 2 weeks. And I don't have a free weekend to do them until the middle of september (weekends go in this order until middle of Sept.: wedding, wedding, help gf move back into her college, beer olympics, something that I am totally forgetting about right now, and then fishing on lake michigan).

Hell I would pay you for 2 if you had the time.