How to Make a Custom Sub Box

[MarkDerby]

Ok Lets start by Finding a Sub box that will look nice in the car
sorry if its been posted a few times before

as you can see its quite nice .. but it does have one Problem
box isnt the right size for the speakers

so anyways this is what im about to show you ...

First you will need some Items from Hardware stores

18mm MDF
2x2 timber
Fiber Glass Resin 4liters
Resin Hardener 2 tubes
Fiber Glass Medium grade 3 meters
Fiber Glass Tissue 1 meter
Hard Brush 2
Pots 5
Fleece about 1mtx1mt
Port Hole ( if your fitting one )

you first have to Prep the place your going to make your mold from
so i used Duck Tape but you can use masking tape too

It would be handy to have some old cardboard too
this will help to make templates

As you can see this allowed me to get the correct shape for the Base part of the box

you need to mix some harder and resin together i did this at 250mm a time with about this much resin hardener all so make sure you mix it well it should turn Pink and have little bubbles this has started the reaction of the resin you will have about 5>10 mins to use it before it start to go like gelly

ok this is where the fun starts
you first need to coat the Mold with Resin
then have your PreCut fiber glass to hand to start applying

once you have done your first Layer of fiber glass leave it over night to set
but why wast time when you can start to make other items needed like the speaker Rings

make sure you have your speaker sizes to hand
i'm making the box for twin 10" subs
total outer size of rings are 11" wide and will have a 9" inner cut out

OK once you have done one layer of fiber glass its time to make some more templates for bracing

 

[MarkDerby]

now you can start to do another layer of resin and then fiber glass
in some places it has 2>3 layers depending on where the weak parts of the box

at some point your going to have to let it set
so next step you will need to take it out of the car/mold and do some cleaning
and shaping of the box

now with the rings you made before you can get an idea of how the speaker box is going to look remember once you have mounted the rings prefit back in the car to make sure you have clearence from the boot lid

your at the point you can start to cover the box
you may need a staple gun ( very handy to have )
remember to stretch the fleece to get the profiles nice

as again before make your self up 250mm resin and then apply all over the fleece where it meets the box and speaker rings

More to come

 

[MarkDerby]

now with the rings you made before you can get an idea of how the speaker box is going to look remember once you have mounted the rings prefit back in the car to make sure you have clearence from the boot lid

your at the point you can start to cover the box
you may need a staple gun ( very handy to have )
remember to stretch the fleece to get the profiles nice

as again before make your self up 250mm resin and then apply all over the fleece where it meets the box and speaker rings

More to come

 

[MarkDerby]

Once the main shape of the box is dry its time to trim the fleece thats not needed

now you can start to apply Fiber glass to harden the box even more
all so once you have done about 3 layers of Fiberglass and tissue around the edges
and its all dry you can cut your speaker holes

Make sure you all so put some fiber glass on the inside to all so i added some bracing to stop box from flexing

more to come

 

[MarkDerby]

Finished Item