Post by
NickD85 »
https://forums.nicoclub.com/nickd85-u123131.html
Thu Aug 06, 2009 2:32 pm
the box itself didn't actually cost me anything to make. I had the glass, the wood, epoxy, and sealants already. But if you were to purchase these things, you could probably build one for under $50. That's a quote for standard glass and polyester resin, and MDF rather than marine grade plywood, marine epoxy, and high strength "E-Glass," which is what I used. The labor is the tough part. I first cut out a large amount of the plastic trunk wall. Next I made a mold of the new space using duct tape, and cardboard. I then covered this "mold" with packing tape, which I then coated lightly with mineral oil. I then began to glass, and laid down two layers of woven cloth. When that had cured I pulled the whole thing out, and trimmed the edges. I then sanded the inside and laid in two or three layers of biaxial E-glass (super strong glass that takes curves well), plus fiberglass diagonals over all the large faces of the box, and another layer of glass. I then cut the plywood face of the box (3/8" marine mahogany plywood), and covered the back face with a piece of woven roving (thick fiberglass). Next the two halves of the box were glassed together. I then made three steel brackets, and bolted them to the car- brackets to which the box is fastened. I finally drilled a hole in the box for the wiring, ran the wires, sealed the hole, carpeted the box, installed and sealed the sub into the enclosure, and fastened the whole thing to those steel brackets. The whole process was pretty time consuming, but i really enjoy doing these things.