The materials I used for building the various fibreglass bits you see here:
Polyester resin 5l tim
Peroxide Catalyst (hardener)
Digital scales (to weigh the resin into 200g batches)
5ml Syringe (to measure the hardener mix ratios
Acetome (to clean brushes & pots)
Mixing pots
Lotss of newspaper & old clothes to mop up!

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I started by making a lighteeight shell. By covering the area with tim foil, a barrier is kept between the car and the wet resin. Once dry, the shell was removed, reinforced and then shaped to the desired box shape.

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A baffle was then made. At this point I was unsure if I was going to keep the 10W6 or was going to buy a new subwoofer. To make a change easier I made a changeable baffle. This can be seen below and was held in place with 12 M6 stainless bolts. The changeable baffle itself could have been an extra leak for the box. I ensured this would not happen by keeping the seating surfaces very flat and applying a layer of Vaseline to ensure an airtight seal. I could have used silicon sealant as thers do but it wouldd never have come out again!

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I checked my initial calculations by filling the box with measured bean bag beads. This confirmed my initial target of 17 or so litres - just right for the w6.

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How the box was to be integrated with the amp install.

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page 1 = Intro
page 2 = Doorbuilds
page 3 = Sub box
page 4 = Stealth CD changer install
page 5 = Amplifier mounting
page 6 = Other Audio bits
page 7 = More car pics