custom fiberglass system problem

[ferruchnuts44]

hey guys, I was thinking about doing a fiberglass enclosure in my trunk of my 2g. I have been researching how to do this rather difficult procedure and I think i'm ready to start. The problem I have is I cannot find the materials. Most people say you can find almost everything you need at the home depot but I've been there and I can't find any fiberglass chop mat to use. Is there a substitute to use instead of this and where could I find one? thanks. Once I figure this out I will be posting pics of the process

 

[92awddsm]

hey guys, I was thinking about doing a fiberglass enclosure in my trunk of my 2g. I have been researching how to do this rather difficult procedure and I think i'm ready to start. The problem I have is I cannot find the materials. Most people say you can find almost everything you need at the home depot but I've been there and I can't find any fiberglass chop mat to use. Is there a substitute to use instead of this and where could I find one? thanks. Once I figure this out I will be posting pics of the process

Home Depot on the same isle with glues and sealers, near the paint area. If not, most local auto parts stores sell fiberglass materials. I hope you are ready for this but I would think not since you dont even know where to look for materials.

 

[brcewane]

hey guys, I was thinking about doing a fiberglass enclosure in my trunk of my 2g. I have been researching how to do this rather difficult procedure and I think i'm ready to start. The problem I have is I cannot find the materials. Most people say you can find almost everything you need at the home depot but I've been there and I can't find any fiberglass chop mat to use. Is there a substitute to use instead of this and where could I find one? thanks. Once I figure this out I will be posting pics of the process

I haven't used any fiberglass mat at all yet on the 2 fiberglass enclosures I have built. I used a method that I found from some professional interior fiberglass guys. Go to your local fabric store and find some "Polyester felt" material that has a little bit of stretching capability to it. The thicker the better.

You then build your frame of the shape you want and where you want your subs to go. Then you stretch the felt over the frame and use a staple gun to secure the felt to the frame (try to put the staples in a place that they won't have to be bondo'd over)

Once you have the felt stretched over the frame you simply get some resin & hardener, mix it up and spread it over the felt trying to totally soak the felt material.

Let the resin setup. Be sure to use gloves and a good canister mask when using the resin and when sanding because the fumes and the dust can seriously mess you up and the resin will become "chemically hot" when curing. Also make sure it is in a well ventilated area because it will really stink up your garage, outside is your best bet.

Once the resin has setup, sand it down fairly well with some 80 grit sand paper with a "palm sander" like a Black & Decker Mouse sander. Then I usually get the Sun Activated 1 step bondo. Go to a shaded area and spread the bondo all over the enclosure trying to get the bondo as smooth as possible with a plastic spreader. You can put this on in layers to build up any weak areas after each coat cures. All you have to do is set it out in the sun for like 15-20 minutes and it will be hard.

Sand.. Sand... Sand.. Sand.. Have a couple beers.. Sand.. Sand.. Sand.. Sand..

And then you are ready for primer and paint. Here is a quick how-to link of what I did before applying the Resin to the fabric. How-To

Here is the finished product after painting.. I don't have any pictures of my new WRX enclosure.. it is in the middle of being wet-sanded and polished.

Oh yeah.. I have always used Marine resin.. go to any boat shop and they will be able to help you out on where to get some.

 

[ferruchnuts44]

thanks guys, your information has been very helpful. I now have the materials I need and I plan on starting today. I will post pics of the finished product when it is completed.

 

[Chuck_3]

i see you already found your material but the local napa i go to has a lot of fiberglass material...just thought id throw that out there...but good luck

 

[4G63 GST]

brcewane .. i have a couple questions myself.

How heavy is the enclosure when its all finished? Did you make small cube enclosures for behind the two subwoofers? Did you leave the big wooden center peice under the fiberglass when it was done to secure it. Was it painted with lots of primer and lots of spray and clear coat?.. or actual car paint? And finally can the enclosure come in and out of the car through the hatch or what.. how do you remove it if you need to?

Thanks .. sorry to bombard you but i was thinking about one for my 1g and i was just curious.

Luke

 

[brcewane]

How heavy is the enclosure when its all finished?

I would have to say about 25lbs without the subs in it.... it was more awkward to hold on to than heavy

Did you make small cube enclosures for behind the two subwoofers?

Yes

Did you leave the big wooden center peice under the fiberglass when it was done to secure it.

Yes I did.. the Mitsu symbol was screwed to the wooden center piece

Was it painted with lots of primer and lots of spray and clear coat?.. or actual car paint?

It was painted with primer and then actual car paint that I had matched to the car color code

And finally can the enclosure come in and out of the car through the hatch or what.. how do you remove it if you need to?

Yes it does come in and out of the hatch... I had a piece of plywood that was secured to the floor of the trunk using existing screw holes. It had some small pieces of wood screwed to it so that the bottom of my enclosure frame would snap in place when you set it in... You could then screw/bolt the enclosure frame to this plywood "false floor". I thought about fiberglassing it right into the trunk but decided I wanted a removable enclosure.

Thanks .. sorry to bombard you but i was thinking about one for my 1g and i was just curious.

No problem..

 

[BlackNWhiteRS]

Hey, not to hate on your enclosure, because it looks very nice, but thats not really the right way to do it.

Using a fleece like material is right, but you want to layer fiberglass mat, cloth with resin over the fleece layer, to make it thick and strong. What you did isnt really fiberglassing, it works cuz you have small low power subs, but if you had bigger subs it might crack.

I'm glad it worked for you, just wanted to let you know, thats not the right way.

here's one of the best free tutorials for fiberglassing: http://web.njit.edu/~cas1383/proj/main/

Also, Walmart even carries all the supplies needed for fiberglass projects.