For my first ever install I tried to do something alittle more advanced. After reading all the tutorials on fiberglassing I found that it's not that hard, just takes a lot of time (and a lot of resin). All the products I used I got at Lowes. There was probably around 35 hours worth of work put into this. Until I get a chance to add text to the pictures, post any questions in the guest book.

They are two .6 cubic feet sealed enclosures for 2 ED 10k's powered by a Hifonics Brutus 1000D. I am not sure how I am going to finish the boxes. Either I am going to use the same type of carpet that the trunk is done in, or I am going to paint them a bright red to stand out. Let me know what you think. I mostly only have pictures of one side or another, but I did the same for both sides.

$lice

Here is a pictures of the left side after I did the taping and covering in tin foil. I put a layer of overlapping tape and then tin foil. I found that the more tin foil you used and the less you tape it down, the easier it was to get off.

This is the left side after 6 layers of glass had been applied. I removed the mold and trimmed up the sides. Fits pretty good.

Same on the right side.

Here is how I cut the MDF rings. I made my own circle jig out of a thin piece of wood. Just mount the router to the board and then make holes for the center and screw it to the wood. When doing this make sure you remember what side of the bit you're wanting to cut on. If you don't pay attention you'll end up with something that's 1/8" too big or too small.

Gluing the two rings together.

This is just showing the completed rings ready to be mounted to the boxes. I add that rope on there to help stiffen up the edges as well as making a place to secure the bottom of the ring too.

I used hot glue to hold the dowel rods to the back of the box. Then I used expanding multi-purpose glue to attach the rods to the rings, as well as to the boxes. I drilled holes in the back of the rings for the rods to go into.

Unlike other people I have seen, I wanted this to add strength to the box. So I fiberglassed in the rods. It can hold a speaker just fine now, so once the glass is over it, it will be very strong.

I used T-nuts in case that I need to remove the speaker at some-point. I had to grind off one side in order for there to be room for the sub.

I cut out a space for the terminal cup, up caulk around it, and then rivited it in. I mounted it on the inside of the box so there would be no problem when it came to having the box fit nicely into the car.

Here is a picture of the box with the "fleece" over it. I justed 100% polyester cloth. It was thick enough to soak up a good amount of resin and streched well also.

Make sure to glue the material to the back of the box. I used 3M spray adhesive. Let the glue dry before you coat in resin, because you don't want it to pull away.

Here it is after the first coat of resin and before the glass. Make sure to soak the backside *where the fleece attaches to the box* first. The do where the fleece makes contact with the ring. Let the dry somewhat... then you can do the rest of the box. You want to be sure the material is soaked all the way through. Once it dries it will be very strong.

Here is a test fit of the left side. It fits really well and looks great in my opinion. Now I will had several layers of glass over the fleece.

Now I have added 3 layers of fiberglass mat. It's very strong now. Once it dries completely I will sand it down to remove and rough spots, then add one more layers and a lot more resin. Once that is dry it will be ready to mount the speakers until I figure out how I am going to finish off the box.

On the last part, when doing the fiberglass, I was getting excited so I didn't take my time. Now this is what it looks like after I sanded all the air bubbles out.

Now I coated both of them in 2 coats of resin and let them dry. They are somewhat smooth now, and this is how they are going to stay until the final covering... whatever that may be.

Since I'm doing a sealth install.. I better hide the wires good too.

The amp was mounted on the underside of the Mach460 box.

Here's the finished project before the covering is put on. I am not sure when I'm going to get around to that though.

Left side.

Right side.

The covering will be coming soon, but will be done by a professional. Probably go with a bright fake leather or something like that to make them stand out.

All and all I'm really happy with how this turned out. It wasn't too hard just took a lot of time. The only thing I think I would do differently is making sure the glue was dry after attaching the fleece BEFORE I put on any resin. Also, I would probably add some fiberglass cloth in between layers to help build it up. In the end I used 4 layers on the top and 6 on the backside and I can stand on it without a problem. Since the broxes are so small I am sure there won't be any problems.

$lice