Fiberglass subwoofer enclosures present some real advantages for a custom car audio setup. First, they can be shaped to fit a specific vehicle or space within a vehicle, taking advantage of space that couldn't be used with a normal rectangular subwoofer enclosure. Second, if properly executed, they can present a real custom look that will make your car audio system truly "one of a kind."
This tutorial shows you how to work with fiberglass to make a sub box located in your trunk behind your wheel wells. Although this tutorial is made to go into your wheel well areas, you could use this tutorial for anything, kick panels, racks, and other speaker boxes. If you have some knowledge of working with glass, then this should be a walk in the park.
What you'll need:
-1 Gallon Polyester Fiberglass Resin
-Additional Resin Hardener
-MDF (For supports, and speaker rings)
-Dremel / Rotozip / Cutter
-A GOOD Respirator
-Disposable Paintbrushes Brushes
-Glue Gun, or Adhesive Spray
This project will not be easy, it will require about 30 hours of work, drying, and adjustment time. Expect at least 8 hours of working on the first day to get your car in order, and get a good pull of your trunk space. In the end you should have a show winning sound set up that will look as good as it will sound.
Step 1: 1. Remove Everything from Trunk
You are now going to need to remove as much as you can from the trunk, everything you may have in there that will get in the way should be removed, even the trunk lid if it gets in your way. The carpet should remain, and you will need to get it as smooth and as perfect to the contours of your car as possible. Use a Vacuum to suck up any debris and dirt that will be in your trunk, you don't want to be dirtying up your box.