Step 1: First Get Supplies for Fiberglassing
You will need:
Concert Speaker (Any will work)
2 Gallons of fiberglass polyester resin
6 Yards of fiberglass matting
3 yard of polyester
4 big tubs of Bondo
Tools I Used:
Spray on glue
Lots of Gloves
Step 2: Make the Frame for the Design You Want
We made the base of the speaker box a rectangle with the front two corners rounded for a nice look.
We then added that thing that looks like a shark fin, that is there for the shape and added support.
As you can see in the second photo we had to cut out a ring that would be there to make sure the 15" sub would fit. I had to use a nail and a piece of string to make the ring an approximate size. I cut it out and filed/sanded until the speaker sat it in snug. We used posts to hold the speaker ring were we want it to be in the final design. The other speakers we did the same thing by cutting out rings to fit the other speakers and had them suspended by the posts. The frames for the speakers have to be abled to hold the weight of the stretched polyester. We then added a back to the box because we wanted that to be flat. You should wire now depending on how many speakers or how much access you have to the inside of the box after.
Step 3: Drape the Polyseter Now
Now i do not have a picture of the fabric before I fiber glassed it but it basically looked the same as the pictures.
When your stapling it to the box make sure that there are no wrinkles or its gunna be more work later. Start from the top and work your way down. As you can see in the pictures we had to go and get more polyester because we didn't have enough. We had that obstacle in the top part of the speaker box we had to put polyester over it after we had finished the other two sides.
Now that you have the polyester on the frame we need to harden it to make it workable. We now had to mix the polyester resin with the catalyst. REMEMBER do no use too much catalyst, i used to much and the resin got so hot that it got burning hot started smoking and instantly hardened, and didnt smell nice either. Once you have it mixed up paint the resin onto the fabric and make sure that the fabric soaks it up well. We waited a full day and tested to see if it had dried with a mixing stick, once we knew it was dried we made another batch of resin and cut 2"x6" strips of fiberglass and started painting them on. If you can paint the fiberglass on horizontaly and when you do the next coat do it vertically. When you are doing this try to make sure there are no bubbles or clumps of fiber glass, its worth taking the time for this instead of spending twice as much time later.
We only did 3 coats of fiberglass, some people say to use up to 7 coats but we felt like it would be strong enough and it turned out it was : ).
Step 4: Start to Bondo
Now you need to cut out the holes for the speakers, for the big ones i used a reciprocating saw and a file and for the little ones i used a 2 3/4 inch circular drill bit. Make sure the speakers fit before you paint.