I have recently started to re-build my entire sound setup. My previous setup was stolen so I must now start from scratch. I won't complain that much since insurance payed for me to get all new equipment. That will sound 100 times better ok well maybe twice as good. For a Headunit I purchased the Kenwood Exceleon KDX-990. Amazing features and has a 5V pre-outs so pretty good compared to others. As for fronts I went with Diamond Audio S600m componets that will be powered off a Diamond Audio D7152. They will be getting close to 170 watts RMS. I won't be adding rears to the car since I don't feel a speaker hitting the back off the seat can make that much of a diffrence. For a subwoofer I went with a Diamond Audio D6D12 that will run of another D7152 bridged so it will be getting close to 600 watts RMS.

For the start of my project which I will be doing entirely by myself. I removed all the trunk panels so I can measure out all the space I have to work with.
I made a mold of my trunk using Darkknight1999s write up.
How to build a fiberglass box

This is the mold once pulled from the trunk. I have made mine bigger then Darkknights because I will be pushing a 12" subwoffer that needs more space and I can always add fluff filler if needed.

This is another pic of the mold. As you can see it came out exactly like the trunk well so I will be guarnted to have a match.

After pulling the mold I am adding more fiberglass to strengthen the box. I am adding longer peices not only to make it stronger but this will also keep it lighter then cutting up alot of smaller weave peices and using alot of resin.

This is a pic of the second layer finished

Now that the second layer has dryed I have trimmed off the excess fiberglass and am now fitting it for an mdf top. I did my last box like this and it came out awesome. It hit hard and I didn't need to make any subwoofer rings.

Now that the mdf top has been fitted I bonded it to the fiberglass using the resin. I let it dry over night and cut the 11" hole for the subwoofer.

At this point the box is ready for my last step on the outside. I am wrapping it in a 1/8" fleece to make it air tight and even stronger. After this step I wil resin the whole box again and cut out the leftover material over the subwoofer hole.

another pic of the fleece wrap


I am about 2/3 the way done with my box and will continue to update the pics as I get farther into the project.. I have alot of clean custom ideas that will be easy to duplicate or change a little for your own taste.
Since that last time I have finished the fleece wrap and sanded the box pretty smooth using a 500 grit sand paper. Below are some pics of the box finished anough for me to continue building th rest of the setup.


This is the box sitting in the trunk well it fits perfectly with out any movement.

After getting it in I started to make the paper templates needed to make the amp plates. I simply used notebook paper and traced the outline of the trunk interior onto it and cut it out. I re-traced it onto cardboard for a better templat that I can use later.

After tracing them on to the MDF board I cut out the peices and fitted them into place. Once again a perfect fit after a little sanding of the sides.

I am about 1/2 way thru this build but to give people an Idea of what I am going for here is a pic. I will have a plate to cover everything but the plexiglass on the amps and over the sub. This way I can still use my trunk and when I am not showing it I will cover it with a peice of grey carpet for an OEM look.

This is a pick of what the finished look I am going for. I might do plexiglass over the sub and cut out the Diamond Audio logo and put a neon underneath to make it glow red.

Well untill I get more time I will post up more pictures for people to look at.

 

Nice work.. i also fiberglassed the full trunk well (p3 12inch) .. need all the space we can get..

post up more pics..

 

Looking good. You should test fit it in the car though, that might not fit because you added the extra material on the outside of the box. But if it was a little loose before you may be ok.

 

I'm no fiber glass expert, but as soon as I saw that he was adding material to the outside I had the exact same thought especially when I saw him adding the fleece. If you want to thicken the walls of the enclosure you should add material to the inside to be on the safe side, correct?

 

my 1st thoughts as well....

i hope it all works out.

 

I have test fit it so many times and it fits like a glove. After this layer I will cut out the top and add any more fiberglass to the inside if even needed. It is plenty strong and still only weighs about 7-8 lbs.

 

Hey, who said you can come to this section!? Get back to waxing! j/k

Although I see what John and Mikey are saying, if he is capable of building the box, I assume he test fitted it.........BUT, we all know assumption is the mother of all.....

 

Bump for new pics