Alright I've been wanting to do something like this for a while. I've been looking around on forums and checking out hard setting up a 15" in the floor of your car be. Now I tried taking the easy way and buying a 15" box, but where I live they wanted 100-150$ to custom make one. So I decided I would fabricate a nice new floor and put my 15" sub in it.
TOOLS/SUPPLIES:
Jigsaw w/ atleast 2 blades (only took me 2 blades) - $4 for blades
Skill Saw (or table saw, to cut straight lines, a Jigsaw won't do this that great)
48" x 48" MDF Board (Medium Density Fibreboard, can be found at home depot) - $25
Carpetting/Vinyl (wal-mart or any fabric place) - i had extra lying around so i used that
Contact Cement or Spray Glue - $?
Power Drill
Step One
Take everything out of your trunk. Unscrew your spare tire (you won't be keeping this in your car anymore after this) and take it out. I believe in most 1g's there are boards that fit around your trunk and spare tire. I
KIND of used those to get my shape. Anyways the maximum width your trunk is 48". So DO NOT cut your board width wise. Use the boards you have in your trunk and trace those on to the bottom corners of you fibreboard. Use some common sense when you do this, your floor is going to be on a angle so cut it to fit that. Look at my pictures to get a better understanding.
Step Two
I quickly noticed I wasn't going to be able to fit the board in in one piece. After some HEAVY thinking I decided to leave the bottom part flat, and angle the rest of the board. So using a skill saw I made a straight cut about 1/4 of the way up from the bottom. Again, look at the pictures below to check out what I mean. I put the bottom piece in first, it took a few tries but I was able to get it in. (I took off the panel where my jack and stuff goes, and then put the one end of the board in there, and wiggled the other end down, then it fit real snug) After that I tried putting the top piece in, and to my satisfaction is went in with minimal difficulty. it sits up against the bottom piece and then it rests on the strut compartment. IT DOESN'T SIT ON MY BACK SEAT!
Step Three
Once your done fitting it (the hardest part) then take it all out. Since I was putting in a 15" I measured the top piece and found the centre of it. Then from the center I measured 7.5" inches each way, and lined up my sub. I then traced my sub onto the board. DO NOT CUT IT OUT YET! you need to measure 3/4-1 inch inside of the traced circle. Remember, your sub needs to bolt down to that, if you cut it out without measuring 3/4-1 inch in, then you basically just wasted your WHOLE project. I was lucky and my 15" fit right in there after one cut. You might have to trim it some more to make it fit. REMEMBER, ITS BETTER TO TRIM A BIT OFF THEN TO TAKE TOO MUCH OFF AND WASTING YOUR PROJECT.
Step Four
After setting putting your box back in your car, and making sure your sub fits nice. (try and make it higher up towards the top of the seat so that it doesn't magnatize to your floor, I have a HUGE magnet and it doesn't touch my backseat and I have it as far as I can get it to the top). After making sure everything fit take everything out again. Time for carpetting. I used contact cement adhesive to do this. I layed out my carpet then layed my board on top. Then I cut out 2 inches away from the board so I can fold that material over. If you think your going to have trouble doing this, just call your mommy. Anyways after you cut out your fabric spray some contact cement on to fabric and the board. When your done glueing your fabric to your board, you should be able to put it right in the trunk. Mine fit REALLY nice after the carpet got put on. I set my sub in place and then using a power drill screwed it into the board (didn't pre-drill them, you could if you wanted). DONE! Hook it up!
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If you notice its rattling (mine didn't luckily) then just stick some foam in where the board and your strut compartment touch. This project took me around 5 hours. It was well worth it though. Hope this how-to helped, if you have any questions just email me. If you haven't already notice, the 1gA cars can't have a flat floor because the spare tire well sits higher than the metal supports, which sucks but whatever. My bottom piece sits completely flat and doesn't move AT ALL, and neither doesn't my top piece. hope you guys have the same luck I did!
1ga Custom Sub Layout
