Just a thread to show the progress on my sub boxes. First off this is my first fiberglass project, so don't flame too much lol. I traded a buddy of mine a Skunk2 muffler for 2 10" JL subs and I wanted them in my truck so I thought I would try my hand at DIY rear underseat boxes. I'll also do a "write-up" of the steps I took.
Test fitting, excuse the dirty interior
So much for storage space lol.
Ok on to my process, sorry no detailed pics of each step:
Step 1: Get materials and make sure you have the tools too lol.
Step 2: Mask your workspace using blue painters tape. I used a crosshatching method, (one layer longways the next went perpendicular). Just make sure your work area is covered to include extra as the resin is messy and not very forgiving to your interior.
Step 3: Take a package of fiberglass mat and tear it into small manageable pieces (about 8"-12" shapes). I mixed some resin and hardener and "painted" it on my tape.
Step 4: Take your small mat pieces and lay them on your tape then mix up about 4oz of resin and the appropriate amount of catalyst/hardener.
Step 5: Apply your resin mix to the fiberglass using a cheap paint brush. The best technique to use is stippling. Fiberglass should go from white to transparent.
Step 6: Next go right into your next layer and repeat for as many layers as you choose (I ended up with 8 layers on my first box and 6 on my second)
Step 7: Relax for a few hours, everything needs to harden. Plus you may need to stretch from being hunched over while layering.
Step 8: Once you are sure your molds are 100% dry pop them out, don't be scared cuz if you did it right it will be strong.
Step 9: Next make your sub rings I did a single ring, looking back I should have done a double so that I could do a flush mount. Oh well live and learn, they'll still get the job done I hope lol.
Step 10: Mount your sub rings using dowels. I struggled a bit here for some reason or another. Once they were "in place" I used fiberglass to secure them, this worked extremely well as once dry the rings were very sturdy.
Step 11: Making your box a box, trim up the edges with a dremel or jigsaw and cut your holes for the box terminals for your wires.
Step 12: Wrap the top and sides of your boxes with some stretchy cloth (fleece) I used a poly-cotton blend from Walmart (I think like 65/35), use 3M spray adhesive and pull the fleece tight.
Step 13: Once dried mix up some more resin and apply directly on the fleece, then let that dry completely
Step 14: Looking more like a usable item, now that your fleece is semi hard from the resin add layers of fiberglass over the fleece, again 5-7.
Step 15: Another trimming session.
Step 16: Finish your box with cloth, vinyl, or paint.
Step 17: Mount your subs and wire them up.
NOTE: Pics show the floor extenders still on, they will have to be removed once completed