Custom Fiberglass Sub Enclosure

[wrightie]

Whats goin on Fockers. Well after researchin on the net i figured i would try my own custom sub enclosures. Its my first time so feel free to laugh real hard :lol: .
I thought i might document it as i went along to show since i really hadn't seen anything like this on this particular sight. Anyways just got started today and hear it goes, wish me luck. Just started by taping off 2inches past where i wanted the fiberglass to go. next step tomorrow

Bubye
Wrightie

[wrightie]

Another angle. (dont worry the box is comin out next step)

[eag182]

Are you using this site: http://web.njit.edu/~cas1383/proj/main/ ?


And please let us know what you got/ where bought/ money spent on each item. I was looking forward to doing some fiberglassing in the future .

[turtles_ride]

i was planning on doing this before the winter, but things got hectic. Now i gotta wait till spring, but it will be nice to have someone elses help who's done it before. Are you putting the tape right on the carpetting, or are you going right against the body of the car. There were a couple real detailed links on this site that i looked at before i decided i wanted to do this. It will be nice to have the boomins and still be able to flip your back seats down to run your snowboard gear thru. Good luck!

[mikegett]

A few suggestions. The tape is ok, but will be difficult to remove from the finished product. I prefer plastic. The large sheets at the hardware store work great. What ever you do chose, use a release agent. Spam seems to work pretty good. The problem with the tape is that the resin tends to drain between pieces. Now comes the important part. Just like any box, the volume is critical for the performance of the woofer. Once you have determined the volume, you will want to incorporate it into the new design. The easiest method is to find something that can be measured and then shaped. Some of the stores like Hobby Lobby carry foam beads. They have a slight moist texture and stick to one another but hold the shape you mold them to. Just measure out the volume using a pitcher and then shape it in your car. The trick is to shape your volume and then do the outer layer first. This enables you to scoop out the foam, plaster, or what ever you used. Then you can do the bottom layer. The third step would be to join the two pieces and thicken the final product. Good luck and let us know how it goes.

[Silentalero]

aluminum foil is your friend ;)

[wrightie]

Wassup Fockers. Well I started step 2 today with the aluminum foil. up until this point i've put 2 layers of tape and the one layer of foil. I might put on the first layer of fiberglass tonight . Wish me luck.

Later
Wrightie

[wrightie]

sorry F****d up

[mikegett]

The problem with aluminum foil is that it wrinkles very easily. The resin then gets between the wrinkles and makes it difficult to remove. If you use a large sheet of plastic it can be stretched smoother. A release agent can be applied to ease in the removal. Then the plastic can be reused as opposed to aluminum or tape. The smoother that the resin is, the less you will need bondo or any other filling agent. They can all be costly, so every bit can help.

[wrightie]

By the sounds of things you are pretty experienced with these sort of things. Most of the sights i visited suggested i do it the way I am up to this point. I think you have a valid point with the plastic and release ageant but I think I am to far along at this point to go backwards. I appreciate your input and any tips relevent to the upcoming steps with be greatly appreciated.

Thanks
Wrightie

[Vtolds]

Just think when you get the mold done you can sell it to the rest of us so we dont have to do so much work.

[mikegett]

Originally posted by VTOLDS@Feb 2 2005, 02:04 AM
Just think when you get the mold done you can sell it to the rest of us so we dont have to do so much work.
He has a point. There are alot of us either too lazy or too busy to do the dirty work. I agree that you are pretty far along to change. My suggestions are more for points to concider along the way or next time around. Fiberglass can be very expensive. The only thing I would suggest to look into would be my comment on volume. The last thing you want to do is spend the time and money on a inefficient box.
When you have finished the overall shape of the box, be certain that your walls are thick enough to prevent flexing. The best method I found was to spray the inside with two to three coats of fiberglass filler. The type used on boats works great and is cheaper. I also placed thin fins on the inside of the boxes to help prevent echoing. The reason square boxes are so popular is due to the lack of waves being bounced back to the coil as in a round enclosue. A dampening fabric or rubber coating will also help to reduce it.

[slowandlow]

i like to line the walls if my sub with polly fill and do about a 50%stuff as long as you have a good sub it will sound good i have a sealed 15 in a 2.5 cf encloser the box is a little on the small side.but i get a little less low end but a better q and a lower group delay

[turtles_ride]

doesn't stuffing the enclosure reduce the volume of the box? maybe thats why your losing lowend slowandlow. also wouldn't the polyfilla smooth the inside and create more of a chance of echoing and reverb?

[Nik1128]

Actually it "tricks" your woofer into thinking its in a bigger box then it actually is.

[wrightie]

Well im back fockers. Step 3 has been a pain in the ass so far. I have done 3 coats of fiberglass so far and I think i will probably need at least 2 to 3 more. Man this is geetin a little more expensive than i thought. Any ways heres an couple of pics to show where Im at so far.

[wrightie]

And here it is in its home. Pretty nice fit if I do say so my self. To bad I still have about 4 months work to go :lol:

[FormulaNERD]

looks pretty good.... 4 more months? all you need is a few more layers, your 1/4" dowels, an mdf ring, and stretch some fabric over it, then glass it :)

[wy3134]

ill go ahead and ask the question, what are the 1/4" dowels for, and where do they go?

[FormulaNERD]

^^^
http://web.njit.edu/~cas1383/proj/Glassing2/13%20--%20mdf%20rings%20mount1.jpg
http://web.njit.edu/~cas1383/proj/Glassing2/15%20--%20prepare%20to%20wrap.jpg
http://web.njit.edu/~cas1383/proj/Glassing2/16%20--%20wrap%20with%20cloth.jpg

[eag182]

FYI those pic are from the link I mentioned above.

[Silentalero]

please tell me your gonna brace those sub rings witha lil more than that? you better be using a poopload of backfiller

[wrightie]

Im baaack. forgot to take a picture of step 4 but all I did was cut out 2 mdf rings to mount the sub woofers. next I mounted the ring with small wood sticks to hold it in place. After that I pulled a T-shirt over it tight and glued it to the back to make the front of the enclosure. Here it is in its home up to this point.

Later ]
Wrightie

[FormulaNERD]

Originally posted by eag182@Feb 2 2005, 08:46 PM
FYI those pic are from the link I mentioned above.
want a cookie? :lol:

that link was posted by richie about 8 months ago... and the guy chris who runs the site is a nice guy, and will respond to questions and stuff in email.

[FormulaNERD]

Originally posted by Silentalero@Feb 3 2005, 01:35 AM
please tell me your gonna brace those sub rings witha lil more than that? you better be using a poopload of backfiller
backfill this :lol: two layers....http://web.njit.edu/~cas1383/proj/Glassing1/25--standing%20on.jpg

[Silentalero]

haha good boy.....ive seen some people not backfill and expect the fiberglass and bondo to hold...dumbasses, lol

[eag182]

Originally posted by FormulaNERD+Feb 3 2005, 10:18 PM--></div><table border='0' align='center' width='95%' cellpadding='3' cellspacing='1'><tr><td>QUOTE (FormulaNERD @ Feb 3 2005, 10:18 PM)</td></tr><tr><td id='QUOTE'> <!--QuoteBegin-eag182@Feb 2 2005, 08:46 PM
FYI those pic are from the link I mentioned above.
want a cookie? :lol:

that link was posted by richie about 8 months ago... and the guy chris who runs the site is a nice guy, and will respond to questions and stuff in email. [/b][/quote]
uh , YEAH!

[wrightie]

Soory to sound like an idiot silent but explain to me why i need backfiller, what to use as backfiller. I am not the most experienced guy when it comes to this so take it easy on me.

Thanks
Wrightie

[AleroBloke]

this is so interesting. I want to do this with my car. I just don't even have a clue where to start, but that guys website (the stoner looking dude) helps out alot. how much would a project be to do both sides of the trunk, i'm talking about everything including carpet. thanks

[FormulaNERD]

Originally posted by wrightie@Feb 4 2005, 03:05 PM
Soory to sound like an idiot silent but explain to me why i need backfiller, what to use as backfiller. I am not the most experienced guy when it comes to this so take it easy on me.

Thanks
Wrightie
you basically need to layer fiberglass on the inside as well, not just the outside, otherwise under certain pressure, it could still cave in. even with a fiberglass shell, those dowels can only support so much.

[mikegett]

I have found the spray in fiberglass to be good for this. It coats thicker, quicker and is easier than squeezing your arm into a ten to 12 inch hole. The marine grade seems to be cheaper and is very affective.

[turtles_ride]

okay guys when your talking backfiller i have a question. Couldn't you just put all the layers of fiberglass on the inside of the back piece until you get it as thick and strong as you want it. Then after you have like 10 layers and its nice and strong, use your dowels and rings and stretch the shirt. Then do all the layers on the shirt kinda the same way but put them on the outside of the enclosure (the side you'll see in the trunk), and just keep adding layers until you get it the thickness and strength you want? Wouldn't that be easier and just as effective as spraying inside your 10 inch opening? Also, wrightie, are you putting a port into each of your enclosures? If so how are figuring out how big it should be, along with your total volume, figured that out yet?

[FormulaNERD]

adding extra layers on the outside isnt the same as adding layers on the inside, the inside is just as essential as the outside, i dont know anything about the spray, but it may be sufficient.

[Silentalero]

use some stuff called tigerhair or kittyhair.

Pkus you need a backfiller simply becasue you want to reenforce the mold but you dont want it taking a bigger shape, build strength from behind and itll last u alot longer..

Tigerhair is what i used for my back seat molds, added quite a bit of weight to it to but its strong like a mofo

[wrightie]

Well im back again. One more coat of glass and i think she is just about done. Pretty happy with how its turnin out. Oh ya and silent, I got a rubberized spray on coating for the inside as backfiller. hope this will be good enough.


Bubye
Wrightie

[AleroBloke]

:popcorn:

[HAZED]

:smokin:

[isellalerodrop]

Whats the t-shirt for over the mold, and to sound stupd im sure what do you put over it more fiber glass or just the resin bevore you lay the bondo?

[FormulaNERD]

the t-shirt is your basic shape, you resin and fiberglass OVER the t-shirt, and the fiberglass takes that shape.

you basically layer the fiberglass and resin. in equal layers, then you can bondo over if you want a smooth finish, or cover with carpet.

[turtles_ride]

if you go to the link on the first page, it says that you use several layers of the fiberglass matte cut into thinner strips so that it curves nicely, and soaked with the resin. the smoother you get the layers on, the stronger the structure is, and the less bondo or filler you have to use.

[wrightie]

Well here it is with the last coat of glass on it. I put a good coat of a spray on rubberized sound deadener. All I have to do is carpet the little mofo and its done. 1 down 1 togo.

[wrightie]

When i finish carpeting the enclosure ill post a pic when it is done but after that i will post a pic when everything is done. It has definetly cost more money than i thought though. nill let ya know how much when im done

Later
Wrightie

[eag182]

Wouldnt that be akward to carpet?

:huh:

[FormulaNERD]

i agree

[Silentalero]

uhh ur not done there buddy, lol

u still have to put the bondo on top of the fiberglass and sand that down....thats the poopty part

[turtles_ride]

i think thats why he wants to carpet it, so that he doesn't have to bondo it. Easier then carpetting (nice car hehe) would be to find a stretchy material that you like and pull it tight over just like the tshirt. Otherwise i'd say bondo and paint it, cuz those curves are gonna be hard to get smooth.

[johny_boy32]

Originally posted by turtles_ride@Feb 7 2005, 08:30 AM
Otherwise i'd say bondo and paint it, cuz those curves are gonna be hard to get smooth.
^Thats for damn sure^ but i cant wait to see final pictures

[sound_xtreme]

i'd proly smooth it out at least a lil, i'd just use Iceing instead of bondo. its A LOT easier to sand.

[Silentalero]

rage gold...best stuff ever

[wrightie]

Well here I am again. Finally finished the first one. I AM REALLY HAPPY WITH THE RESULTS. It has taken me a hell of alot of time to do so far, but like I said it was my first time and im sure to get better. Started the second one tonight and it definetly went alot quicker. Ill post a pic of both in the trunk when im done. should be 2 or 3 days.

Later
Wrightie

[johny_boy32]

I'm no expert but that looks damn good man...how much you want for it...lol...kidding. Very nice job.

[Cyber Knight]

That does look really good, how well will a pair of those sound compared to a box?

[FormulaNERD]

come on tease! show us what it looks like in the trunk

[stealthlero]

hey wrightie that looks awesome... keep us updated w/ the pics when yur done... i would do it but don't am too lazy to do it, and i got other things to save for!! :thumbsup:

[AleroBloke]

that is no fair, he could have taken a picture of the one he finished in the trunk! haha. big tease, seriously, how does that compare to a box? sound i mean. Also dude, you could make some dough and just make them and sell them on this site, they would be very popular to us lazy bastards!!!! I would fork over the cash!

[wrightie]

Hey guys i figured i would throw a quick post to tell ya about the sound of the new enclosure. Now im not just sayin this but i am literally blown away by how good just the one sounds. The bass seems tighter and alot cleaner. i cant wait to have the other one finished. 2 more days. Alright no more teasing here she is.


Dont laugh you profesionals, take it easy on the amatuers.

Wrightie

[wrightie]

Oh yaI probably spent about 200 Canadian on these( about 160 American) and trust me I would charge way to much to make it worth your while. Its not that its hard its just time consuming.

Thanks for the support
Wrightie

[kwhauck]

looks pretty good.......props for the hard work man......

[Vtolds]

Looks good, it would look better if the carpet matched. How long till you get it all hooked up and thumping?

[AleroBloke]

me like, i knew someone would bitch about the mismatched carpet! haha, anyway, it looks so tight dude, good job,

[alerosmoke]

kudos. :thumbsup:

[rmulax19]

Originally posted by VTOLDS@Feb 8 2005, 09:57 PM
Looks good, it would look better if the carpet matched.
VT, you are a jack-off. i would bet my life on the fact that you would never have the drive to do anything half as involved. for as much work as he did, the carpet matching is the last thing he should be worried about. he still has a whole nother enclosure to do.

even some of the experienced with fiberglassing commended him on a job well done and i commend him. i would never be able to do something like that.

that looks so close to stock, it's amazing.

[eag182]

calm down he was just giving his opinion, no need to blow this (awesome) thread apart

Excellent Job wrightie!

[wrightie]

Not that it matters but I guy because the texture of the fabric it looks different on film, but in person it looks like a perfect match. Anyways you cant make everybody happy but I guess the most important person is happy and that is me.

Thanks for the feedback
Wrightie

[wrightie]

RMULAX :thumbsup:

[FormulaNERD]

Originally posted by wrightie@Feb 8 2005, 08:55 PM
Oh yaI probably spent about 200 Canadian on these( about 160 American) and trust me I would charge way to much to make it worth your while. Its not that its hard its just time consuming.

Thanks for the support
Wrightie
160 for the pair? or each? i could see someone paying around 250 for a pair if the volume was right for the sub they wanted... hell q-logic kick panels are like 140, and thats nothing compared to this.... i know i'd pay 250 for some good sub enclosures.... though i'm not sure how much you'd charge for your troubles.... and it would be easier if you made one set for the mold of the bottom half, and then duplicated that. and buying fiberglass stuff more in bulk would lower the cost aswell.

[Silentalero]

i guarantee you these would NOT be $250 a set simply because companies will charge you $50 an hour to make a fiberglass enclose so something like that would cost around $500-$1000 a set.

Nice job dood, the carpet does look off but im sure its the film, my camera does the same with my car and colors. But for a first time its a really nice job.

[johny_boy32]

agree, that looks awesome man. You really jumped through a loop on this one. It looks very good...and IF you think you want to make them for people you should jack the price up. If not for materials for all the labor and time you put into it. Nice job again man.

[mikegett]

Hey wrightie, where are you? Are you going to keep us in supsense or show some more pics? I agree with the earlier post. You should think of making a mold for the enclosure. All you need is a little plaster (very cheap and sets up in a few hours). You never know when that it may come in handy. Hint. Hint. :thumbsup:

[Silentalero]

materials arent what cost, its th time and patience, and even then he didnt get the normal front of the blow of fiberglassing....try bondo'ing a mold and sanding it for hours and hours to make it perfect...now thats a bitch.

[wrightie]

Yep. I agree I took the bit** way out. I honestly didnt have the time or will to as im sure you would agree, do i right. But im really happy with how it is turning out. I am almost done the 2nd one now. I am lookin forward to posting a pic of the finished product i think it is going to look really good.

Later
Wrightie

[gxryan]

That is really sweet doesn't look to nice until it's all said and done and put in...

hmm well being as i mite have alot of time on my hands this summer once i am done school. I may have to take a stab at this myself :D

looks cool though.

[mikegett]

Don't worry about it. Most of us here are pressed for finding time. I bought my system in August and it is still ony half done. The doors have been taking forever. Between moving and working seventy to eighty hours a week I was pooped. Then, when I finaly had time, it was too cold to glass anything. I have been driving without a door panel for so long that I almost forgot what it was like to have a handle, power windows, and no one staring. In short. Just do what you can be happy with and remember that there will always be support for you here.

[wrightie]

Mike U R Definetly the man :thumbsup:

Thanks Buddy
Wrightie

[wrightie]

Well after 2 weeks of fu*king around I finally finished my enclosures. I think they look pretty sweet and it really opens up my trunk space. the sound is totally sweet and was quite suprised to find it sound better than the ported box i had. Well obviously the box is for sale now btu with shipping it probably wouldn't be worth it to anyone in the states I only want 50(can Funds)$. If any one local wants it PM me.

[FormulaNERD]

looks pretty sweet bro.... great job

[stealthlero]

definately an awesome job wrightie!! so what was the grand total like for doin it all?

[mikegett]

I agree. What was the total amount of resin in gallos used? How many layers were placed onto the forms? Thanks and it looks great while saving space.

[Vtolds]

Looks good :thumbsup: I dont see a difference in carpet now.

[wrightie]

Total Used

1 1/2 Gallons of Fiberglass resin 120 Dollars(CAN)
Cheap Brushes about 20 from dollar store- 5.00 dollars
Fiberglass Matte 4 Packs about1 1/2 meter by 1 1/2 meter 28 Dollars
1 roll 2 inch tape 4 dollars
1 package of tinfoil 3 dollars
1 square meter of MDF 6 dollars
Fabric from fabric store for 17 dollars


Total 183.00 altogether, took about 2 weeks 2-3 hrs a day.
One F**k of alot of patience.

Later
and thanks for the good feed back
Wrightie

[mike2002]

looks freakin awesome....you'll definatly have some buyers for those when you sell the alero or crash it like everyone else lately (KNOCK ON WOOD!)

[stealthlero]

Originally posted by wrightie@Feb 13 2005, 10:39 PM
Total Used

1 1/2 Gallons of Fiberglass resin 120 Dollars(CAN)
Cheap Brushes about 20 from dollar store- 5.00 dollars
Fiberglass Matte 4 Packs about1 1/2 meter by 1 1/2 meter 28 Dollars
1 roll 2 inch tape 4 dollars
1 package of tinfoil 3 dollars
1 square meter of MDF 6 dollars
Fabric from fabric store for 17 dollars


Total 183.00 altogether, took about 2 weeks 2-3 hrs a day.
One F**k of alot of patience.

Later
and thanks for the good feed back
Wrightie
Havin 2 kickass sub boxes that nobody else (on this forum that we've seen) has!! PRICELESS!!

['04 aler-ho]

excellent job wrightie!

q logic can sell stuff cheaper cuz they mass produce it. they make hundreds of them in a day. and trust me, q would not sell 2 sub boxes like that for 200-300.
maybe 450 or so. hell their kicks are 140.

now for the question. how much of a demand is there? i would make a mold large enough to cover about a third of the trunk. and you finish. that should be enough air for 2 12s. that means i would go from the wall to the spare tire cover. 8oz of f/g. that is thick. hell fishman only uses 6. that way you can trim it down to size. let me know.

[teebo7]

Hey I have a question I know this is an old topic but how do you measure for the correct amount of volume each sub is needed in a fiberglass enclosure?

[snake_eyes2]

A couple of different ways, The less messy one is to take your shell and cover it (t-shirt/fleece/w.e) and then fill the box with packing peanuts. measure the volume that they take up in another cnotainer and volla. You have your air space. Some of the other messy methods involve math (cring) or using water and garbage bags (shakes head). Good luck

[teebo7]

another container? like a box?

[BLK03GXS]

Well i would use something that was a calculated mesure... like a 1L popbottle... or a one cubic foot cardboard box... for example..

[snake_eyes2]

Originally posted by teebo7@Apr 26 2005, 03:59 PM
another container? like a box?
Quoted post



Another box can be used because you know the dimensions of it.

[wrightie]

Anyone who wants a set of these made can shoot me a Pm. It will take about 7 to 10 days to make but if there is any interest out there I am lookin to make alittle money on the side.


Wrightie

[snake_eyes2]

I have also thought about this (will take pics when I am sone the first one) but my time would be expensive.

[teebo7]

wrightie just wonderin how you measured for volume? I'm in the process of attempting this myself in a different form. just wondered how you measured. Thanks

[per0xide]

if you were to go from side to side, like '04 aler-ho was talking about, except make it a lot like wrightie's old box was.. (i dont care about trunk space) what would be the best method of doing that?

sorry for the vague question, but i've never done fiberglassing either..

[alerospeed2003]

those look awesome man......i might have to try to get some from you :thumb:

[snake_eyes2]

Originally posted by teebo7@Apr 28 2005, 02:25 PM
wrightie just wonderin how you measured for volume? I'm in the process of attempting this myself in a different form. just wondered how you measured. Thanks
Quoted post



^^^ Look up just above your post.

Make a shell, cover your shell, fill shell with packing foam, put packing foam into a regular sized box and measure.

Option two is to draw a scale version in 3D and then using complex mathmatical formulas you can get the air space as well. But man math is hard.,. :wacko:

[wrightie]

well here is the new addition. I think it looks pertty sweet.

[johny_boy32]

pretty sweet indeed. It would look a hundred times better if it wasnt for all the wires everywhere.

[wrightie]

the wires actually are all gonna be hidden I was just excited at actually being done and got a quick snap shot of it.

[King Asoka]

wow man, very nice. Is that a third sub? if so what type? and what model JL's are you running?

[turtles_ride]

those look killer, did you measure the volume on them this time???

[wrightie]

The subs on the sides are W3's and the bad boy in the middle is an earthquake subzero. 750 RMS. Its a sicko. As far as measuring the volume I just made sure I was in the range for the recomended sealed enclosure, So ya sorta.

Wrightie

[wrightie]

I figured I better get this done before good ol johnny boy had any more negative comments the devoted proffesional that he is. Here ya go johnny, hope you approve.

[wrightie]

Heres another view

[RoninKouga]

OMG I WANNA HEAR THIS CAR!

[pawzbear]

I like how its finished with the carpeting, looks very classy, not ricey. Awesome!!

[boarder211]

Damn man! That's looking awesome! Great job!

[FormulaNERD]

looks good, but with all that work i would have went totally custom and glassed the whole trunk, smoothed and painted.

[sound_xtreme]

Originally posted by FormulaNERD@Jun 20 2005, 02:12 AM
looks good, but with all that work i would have went totally custom and glassed the whole trunk, smoothed and painted.
Quoted post


agreed

[ptrudel]

^i agree with that too....but damn man, that looks AMAZING...great job :thumb:

[johny_boy32]

Originally posted by wrightie@Jun 19 2005, 07:21 PM
I figured I better get this done before good ol johnny boy had any more negative comments the devoted proffesional that he is. Here ya go johnny, hope you approve.
Quoted post

Hey man, sorry if I came off as a d*ck, I was just saying it would look better if you did that. The setup looks awesome and it looks like your hard work paid off. Sorry if I offended you.

[snake_eyes2]

Very Nice job, wish I had the time to finish mine off. But good job none the less.

[BLK03GXS]

Drool... nice.. i just have to get mine done now...

[AleroDante]

Just finished my sub enclosures tonight. Not even close to being as pretty as wrighties, but i'll get some pics up here when I get them in.

[Silentalero]

looks good, i like the idea, but your edges are wavey. i can see it in the light, unless im seeing it wrong

[polarexpress17]

heh, yea i gotta say they are gr8 lookin man, but if you wanted to do some sanding (my favorite part - odd) that would look totally pimp bein all glassed in like an ocean blue or somethin

[slowandlow]

how many cubic feet are thoes enclosers?