I need a DIY spare tire fiberglass box for a 2G AWD

[dsmracingofco]

Before anyone jumps my case, I have done a ton of searching and have found some very good articles, but nothing for exactly what I want to do.

Now that is out of the way, I want to sink a 10" DVC Eclipse Aluminum sub in my spare tire area. Nothing fancy, but stealth, totally hidden with full use of my trunk.

I am asking for a how to with a step by step procedure for putting a fiberglass box with one 10" in the spare tire area, pics would be awesome!
Some questions that I was not able to find, is what do you do with the washer fluid container? I need it to still work, where can you mount it? This is a daily driver, with performance in mind, so the lighter, the better. Also needs to be removable for whatever reason. How do I mount the top to the fiberglass? Can I do the whole thing in fiberglass. What materials did you use so that you could lift the box out? Approximately how much volume is in the spare tire area? I need .75-1.5. I called the tech line for eclipse, and for my type of music he suggested a sealed 1.5 box.
What are the best materials to use and cheapest place to get them? I have not searched on this area, so forgive me please, but I have searched many other forums and message boards, and have not found exactly what I am looking for.
Thanks in advacne,
Chad
97 GSX

 

[98eclipse]

Thats a pretty loaded question. But I think I can help you out. I have seen this done a lot. You will probally not have the WHOLE things fiberglass because It would not sound right if the whole box was completely made from it. Here is how I would do it.
1. spray the inside of the spare tire area with a release agent. You can by this at any home improvement store.
2. lay a layer of resin, while resin is still wet lay down a fiberglass mat and lay another layer of resin over it.
3. wait to dry. It dosn't take to long for fiberglass to dry. lift it out. That is where your release agent comes in.
4. I do not know the exact dimensions of the spare tire area in our cars but if it is to big then you can easily cut from some MDF board some dividers and insert them in your mold securing them however you like.
5. Cut a piece of MDF board to cover your mold. Cut a 10" hole for your subs in the center of it. carpet it or whatever you like.
6. if you used dividers in your mold wich you probally did, use the tops of them to secure the lid of your mold to with screws. now when you want to remove it just lift on your carpeted lid and the whole mold will come out with it.

That is just a quick idea of how I would do it.
supplies
resin
mat
gloves
mdf board
paint brushes
release agent
all can be aquired at home depot, lowes or whatever is near you.

ps as for your washer fluid you can relocate that were ever you like.
good luck
pm me if you have any questions if i didn't make some parts clear.