Passenger's side kick panel 100% stock before custom kick panel fabrication began.
Here you see the drawings of the kickpanel baffles drawn onto scrap 3/4" MDF I had lying around from building the sub box.
This is one of the kick panel baffles after it has been cut out with a jig saw, the tweeter hole drilled out with a circle cutter drill attachment, and the midrange mounting flange section cut down a little bit with a router to give the speaker more of a flush-mounted look.
Kick panel inside the car lined with garbage bags and tin foil to protect the rug from the fibreglass resin.
This is what the pod looks like after the mold has a few layers of fibreglass, is cut to shape, and is attached to the baffle with lots of hot glue and dowel rods.
Many hours of fibreglassing the sides, body filling, and TONS of sanding later... I ended up with this. I painted it with car paint after a few coats of primer.
Here is is after the speakers have been installed and the grilles put in place.
Finished & installed.