Fiberglass subwoofer box molding idea

I have been building a fiberglass subwoofer box, but I am not happy with how it is coming out. It just feels way too rough, there are too many steps involved with the fiberglass, too many joints. I know sanding will make it better, but I think the process and prep can be made better.

So in a search for making this better, I have come to the conclusion that I can mold the entire box in a single shot with mdf speaker baffle and both front and back of the box all molded at the same time.


Here is my idea.

In the rear cubby, there is a plastic panel at the bottom, its removable.
So I removed this panel and it gives me a very large access to the inside of the cubby.
My thoughts are that I can cut some wood, cover it with aluminum tape, screw the baffle to the front of it. Then I just clamp that to the front of the cubby (would need to be 2 parts to follow the curve on the front)
After that part is secure, I can then fiberglass from the inside of the box using that access hole in the back of the cubby.
Once its all cured, I can remove the screws holding the baffle to the front panel, remove the front panel and I have a perfect flat, and formed front baffle. Cut the speaker hole out, then I just have a big square hole in the back of the box that I can just put a wood plug into and fiberglass it down.

Im going to try this out next weekend to see how it goes.

 

Back side of the panel with the access door removed

bottom view looking part way in

camera inside panel all ready for fiberglass

 

First layers of glass down, need to add a few more

 

Box is coming along, time is short, so I can only do little at a time. But the one price build seems to be pretty good. Getting into the top part with the fiberglass was a pain. If I had to do it again, I would all the seems and corners first, then lay the big open parts last.

 

You can use thin layers of body filler to help shape and smooth it out.

 

Awesome box build! I’m looking forward to seeing more progress

 

Wait so the whole rear of the cubby comes off? And this is the stock cubby without the OEM subwoofer right?

I may need to do this down the road. I have 3rd gen cubbies in my 2nd gen and have always wanted a form fit enclosure.

 

Yes, im going to sand the whole thing, then using bondo hair and foil tape I will be forming the corners better. I figure I can put some bondo hair in the corners, then press the box in nice and hard, clamp it, then let it harden. This should give me a pretty good shape of the corners. Going to do the same thing around the actual subwoofer... put the sub in, wrap a layer of foil tape around the subwoofers rim and then put in filler so the sub is part recessed.

Thanks!

 

Yes, this is the drivers side one. If you remove it and look at the back, there is a removable panel. When its removed, it gives the enclosure space to tilt and slide out nice and easy.