I used to hate working with composites, but that was before I knew of the different kinds of resins so I just used the cheap stuff at the hardware store. Yeah I was thinking of the vacuum bag method, I guess I was thinking about heating it also. If you decide to place your (c) Copyright 2019 - James Buck - The enclosure is the first thing you should consider after buying a subwoofer. I buy cheap paint brushes by the box, the foam kind also works. True, epoxy is more expensive, but not prohibitively so ($75 for 1.5 gallon kit at U.S. Composites). Electrolytes, Theyre What Dehydrated Hackaday Writers Crave! I learned many years ago from watching a video by Robert Garza of Select Products that premium resins are red in color; green is an indication of a mixed batch of leftovers. I managed to hit 0.74 square feet by subwoofer enclosure for a 12" MB Quart Subwoofer. completed, move on to the more complicated portion of the custom :). When using a different fabric I think you end up the possibility of delamination as you just have resin coated fabric. Protecting The Hughes H4 Hercules With Beach Balls? Acura - MDX 2007 - 2013 SUB BOX SUBWOOFER ENCLOSURE STEALTH LOOK, Acura - TL 2009 - 2014 Magic Box Subwoofer Enclosure Custom Stealth Sub BOX FIBERGLASS, Acura - TLX 2015+ 2016 2017 2018 Magic Box Subwoofer Enclosure Custom Stealth Sub BOX FIBERGLASS, Cadillac - 2015+ 2015-2020 ESCALADE TAHOE YUKON SUB BOX 3X10" DOWN FIRING SUBWOOFER ENCLOSURE STEALTH STORAGE BIN SUB BOX, FJ CRUISER STAGE1 PACKAGE AUDIO UPGRADE STEREO STAGE 1, FJ CRUISER STAGE2 PACKAGE AUDIO UPGRADE STEREO STAGE 2, Honda - Accord 08-2012 Sedan Magic Box Sub box Subwoofer enclosure, Lexus - IS300 01-05 MAGIC BOX DRIVERS & PASSENGER SIDE Sub box Subwoofer enclosure. If you believe theyll be too noticeable, paint them black or another color. 
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Laminating epoxy is thinner than polyester resin and wets cloth/mat more quickly. CV Based Barking Dog Keeps Home Secure, Doesnt Need Walking, Foam Cutter Moves Like A Hot Knife Through Butter, Go Big Or Go Home: 0.6 Mm Nozzles Are The Future, PERSEUS-9, The Dual-6502 Portable Machine That Should Have Been, Hackaday Prize 2022: Modern Plug-in Gives TRS-80 Its Voice Back. If you do not reinforce the process. This is a great deal of fun! The resin can be stippled in using the brush or poured on directly and then spread with the brush making sure it soaks in thoroughly. Most of those custom cars you see at shows with fancy molded interiors are hiding many pounds of MDF, wood and bondo. BTW thats the partial answer to the question I ask at the end of the video where I mention why I keep an oven in my garage. We hope you enjoy shopping at Wicked C.A.S. 
Excellent article and video. a fiberglass mold from with a generous helping of Vaseline or release wax. Essentially, you create a "baffle ring" which will be the ring you Instead of that, atrick I picked up from the Car/Audio magazines is to use spray adhesive and cover the tape with a layer of aluminum foil as it forms an excellent liquid-proof barrier and then separates easily when needed. factor" was 0.75 square feet. We'll walk you through casting a fiberglass mold of your trunk and using it to create a DIY speaker box. portion of this fabrication. power and sound quality. This is where going to the local salvation army for supplies makes sense as well. rH0"w3.r)meK.J$$ @IlYi'g$+-"3['^^j Congrats. Thank you for joining our new online store front. a flat piece of MDFB. make the initial "layup". I learned to make fiberglass molds from poliester resin its cheaper, Please be kind and respectful to help make the comments section excellent. Once the fiberglass Depending on the finish desired you could use metal glaze and high build primer and repeat sanding until its smooth as glass, then paint with a high quality automotive paint. This allows you to pull the finished mold out of the original spot without strength, proceed to finish the fiberglass process by sanding and laying Always wanted to I use Rage Gold polyester body filler applied very liberally to the project.
It does take a little practice to get things right and getting two pieces to match can require some patience. The polyester fleece melts a little with the resin, I assume that acetone is to increase wettability? Remember that polyester fiberglass resin is a dangerous product, so use a dust mask or respirator, gloves, and goggles when dealing with it. Please be patient at we are slowing trying to work out the kinks. Construction is the business that connects and runs 24 other businesses. Scion FR-S TOYOTA 86 Subaru BRZ - 2011-2019 Fiberglass subwoofer Enclosure stealth sub box Custom MagicBox Magic Box. Its all about the polyester resin, which is used to impregnate a variety of materials including matting made of glass fibers and/or polyester fleece. I havent done fiberglass in a long while, Ive done many a sub woofer box in the past, cant say I miss the mess and the stink. To begin with, it can be shaped to properly suit the shape of your trunk and mimic its features. At the same time, all the materials needed to make a custom box will be substantially less expensive ($100 $150, depending on the fiberglass you choose for your project). Once theyve run one around the show circuit for a year or two it begins to look a little tired so theyre off to do the next car. ImThomas Moody, also known as Guitarzan. matter what. You can even use denim. Nice to see a mix of articles on hackaday. This article has been viewed 48,059 times. No fibreglass. Could you use the original as a vacuuform buck as well? A staple gun or even cyanoacrylate glue can be used to affix it, I use an air powered staple gun that puts down an impressive rate of fire. If you're looking for a slick way to install a car speaker or subwoofer in an oddly-shaped space, you can create a custom fiberglass enclosure that fits around the wheel wells in your trunk. Positioning the speaker rings to angle the speakers in the desired direction and height can be done any number of ways, I use little sticks cut from MDF to build supports for the rings using hot glue or epoxy to hold them in place. The minimal price for the fiberglass enclosures starts at $200, so even the cheap model will set you back more than the subwoofer. The process of hand-crafting a fiberglass subwoofer box takes more than 24 hours. custom-subwoofer enclosure. If dust collects on the fiberglass resin, the entire process will be ruined. In the video below, I make a simple speaker pod meant for mounting a speaker to the surface of something like a car door. Once you have finished the Using a pencil, draw two circles around the subwoofer on the MDF board (youll need two rings). simply filling the dead-space in the bottom compartment with fiberglass. Remember to make the shell bigger than you actually want it to be as you will be trimming it later. Speaker Pods / Panels / Adapters, MITSUBISHI - EVO X 10" or 12" Magic Box Sub box Subwoofer enclosure, Toyota - 93-98 Supra 1x10" MagicBox Enclosure Sub box Subwoofer enclosure, Nissan 370Z Corner 1x10 Enclosure Sub box Subwoofer enclosure stealth look, 45 Route 125 Unit 1, Kingston, NH, US, 03848. Hi everyone! A good epoxy resin, under a vacuum bag to get rid of bubbles and give a more consistent thickness, cured somewhere between 150*F and 190*F, will give an excellent result. www.techguys.ca. Trim the edges using a jigsaw or a die grinder (they will be very uneven as you pull the enclosure out). I will however re-create this project come spring to better illustrate the Otherwise, your box will be moving while you are driving. I have seen some people coat the tape with mold release wax or spray Polyvinyl Alcohol (PVA) as a release agent. to your left, I did not take the time to snap any photos of the process. It will be laid down in a papier-mch style. The mat comes in big pieces that are torn into smaller manageable piece and then impregnated with resin, building up the structure while eliminating trapped air bubbles. My last set of pods used thinner, less heavy plywood. Commonly a glass strand mat is used for building up thicker structures.
You should also beware of air bubbles because they can weaken your box. Tip: Fill the enclosure with water, then in measured portions, You can speed this up by using a blow dryer. and is thusly not reccomended. http://imgur.com/a/09CDu, were you on mp3car? (Comment Policy). . About the praise for epoxi: yes. I went the other way in the video and sprayed it with a rocker panel textured spray product by SEM. Yes, once the resin sets it will be the resin holding everything in place. Toyota - FJ Cruiser Rear PODS. I typically buy some rings and then use them as templates for use with a flush cut router bit, or I go ahead and cut them out using a jig saw. It was pretty sweet with a VIA C7 mini-itx, but these days the factory head unit is much better than most home-brew solutions. Apply a basic layer of the mixture to the area where you want the box to be with a paintbrush. In my case, the ideal "Q sure you mask off anything that you don't want ruined by fiberglass resin. Heh, I forgot all about mp3car, used to be I was always planning for the ultimate car computer. Excellent tutorial, do you ever use a bit of acetone to thin the resin in the first stage of coating the fleece? Yeah the stink is mostly nostalgia for me at this point. Being polyester, the fleece melds well with the resin and becomes fairly solid. I could do a whole post on using a small table router to do things like recess the speaker or rounding off the speaker ring, however the same things can be accomplished using two different size rings or by hand sanding the ring to round it off. If I had titled it Custom Resin Impregnation I dont think people would have had an intuitive understanding of what I meant. In this project, we made use of I buy a new gallon every summer, though I have hit a few years where I may not have gotten around to actually using it that year, dont tell my wife. down a gel-coat for final finish. So the title of both the video and article say fibreglass, but in the first (and biggest) example you dont even use fibreglass? It will be difficult, so you will have to put out some effort and may require assistance. wall _extremely_ strong. Once removed the tape is peeled up leaving a clean original surface and a newly created fiberglass piece. Thanks to all authors for creating a page that has been read 48,059 times. AVR has updated the project titled Rosie. There must be a ton of stuff on the internet about home-made pre-preg carbon parts, but the one that springs to mind for me is this one http://www.danstuff.info/furybuild2.htm on the interior panels section http://www.danstuff.info/panels.htm He describes how he made his oven out of MDF and bits of an electric hob.
But at the end of the day I usually get something similar to what I envisioned and that looks cool and unique. I would think the resin would seep through the fleece and stick it to the MDF. AVR has updated components for the project titled Rosie. Back in 2007 I did a spare-tire subwoofer/car pc project. warnings, directions, etc. If you have any questions please email or call us. lycra over your project, you then bathe the lycra in fiberglass resin. enclosure: the baffle. I havent seen the video (payg internet) but the article is great. At least if you do not need aerospace level parts. Probably because I rushed it Im assuming. Its also more durable than wood (although some craftsmen choose to blend the two materials). Once you work with a good epoxy resin youll never want to go back. As my son had raided my stock of really good masks I ended up with my half face filter mask when the video wasnt running. I know it is more expensive, but it is stronger and easier to mix. Apart from the above post, fiberglass is used in many other areas, such as construction. No autoclave necessary. "fji?0lq;3\NiQ0h)s}]^m})5TWa\BNG/9!xBi/Fn 6%b|4gj)H q1Wm @6,9P+Z6!45*7W6 H (4 G).-pvfY\Xyz5cgKh>' f5>$9yA[^ZA*4BI _ ;)6}ETtJHA=>sw.a5LZnG'"$hB, I think its over 6. strengthen the walls - this is absolutely critical. D`{ C >5Zo)*)UK 6>NAEmlJ&h. possible to the "Q factor" of your subs. has had a chance to set, you are then ready to remove the mold from its The next part will include you measuring the bottom portion of the I use it too but since I had a professional laminating guy on my team I am *SUPER* careful with the stuff bisphenols are screwing up a lot of hormonal processes in the human body with effects ranging from allergies, diabetis to cancer. I do show my table router in the video but do not turn it on due to the noise and mess it would make in the middle of shooting a video. I tape down a drop cloth and then cut a hole and tape the edges. Once you are content with the structure's 76(5k }Kon/jk&_R4.e+ZB 3g xGF]/|8.dFs This is a One note is that a big subwoofer requires a lot of rigidity which might take an immense amount of fiberglass to achieve by itself, so its common to combine MDF and fiberglass (and acoustic dampening material) for the best effect. A primary concern when getting resin anywhere near the interior of a car is protecting the car from all parts of the permanent mess of the resin. I havent watched your video, just read it here. of air inside the enclosure. Been there, done that.. got into a lively debate with the boss as he thought Id forgotten to add it to the resin when it failed to harden. air volume for installing a 15" subwoofer without sacrificing trunk space. When I think of making messes with a degree of permanency, I think of fiberglass. material) over the entire project - sort of like a tent. The other ring will be glued to it for screwing in the subwoofer. Tip: If you have access to an air compressor, use an air blower Include your email address to get a message when this question is answered. But the whole process, including the mess, is worth it for the amazing shapes you can produce for speaker pods and custom enclosures. enclosure as opposed to carpeting it. Aaronbugno2 liked 80speak - Online DECTalk Speech Synthesis. Its also a highly customizable enclosure. our techtips section for more information. I havnt but it sounds interesting. Utilizing fiberglass for something like a custom speaker pod for a car is not difficult, but it does tend to be tedious when it comes to the finishing stages. Lay down a layer of fiberglass before the resin dries. You can even replace your entire door panel with a slick custom shaped one with built in speakers if youre feeling adventuresome. Its important to note that, while this project isnt tough, it will necessitate a lot of steps and patience. The implication is that a premium resin is from a production run and not the odds and ends of other production runs. Once the Once the initial form is free Simply install the terminal block for too much trouble. Once the area is masked off, coat the area you plan to make All tip submissions are carefully reviewed before being published. If you have ever done bodywork on a car you know what kind of mess and effort I am talking about. drinking fiberglass resin is a good idea - you're on your own. Before you begin glassing, its also a good idea to lay down something like newspapers all around the work area. Learn more, How To Do Beautiful Enclosures With Custom Fiberglass, These Are The Twenty Finalists For The Hackaday Prize Best Product, Why Fedora Decided To Give CC0 Licensed Code The Boot, Where Pollution Hits The Road: The Growing Environmental Hazard Of Rubber Tires, The Surprisingly Manual Process Of Building Automotive Wire Harnesses, Biomimetic Surfaces: Copying Nature To Deter Bacteria And Keep Ship Hulls Smooth. enclosure as well. Next a fabric is stretched over the frame formed by the rings, my favorite being a polyester based fleece that can be purchased at craft/sewing stores. Then sand it down, add another coat, repeat. Or does it become part of the final product? nolandoktor has updated the log for Vortex Watch. This site uses Akismet to reduce spam. dead-space in the spare-tire well - this is a particularly good source of I do my own custom fiberglass because I enjoy it, (not the part with pinholes that mess with the finish) and if I do it right I have a custom look that could have otherwise cost some serious cash. I always leave any extra resin in my mixing container and set it near the part so it has the same cure conditions. If you have any from the car, continue to add more layers of fiberglass to the inside to Slow, medium, and fast epoxy curatives are available so you can select whats best for your working time and temperature. flammable liquid on earth). Now Im rebuilding the dash for round two???? If you want to save weight and for some things have more room inside the housing, go to the extra time and work to make a mold from the piece then layup a new part in the mold. Wear a mask or a respirator and goggles and only do it in a well-ventilated location. Place the rings on the box and secure them with dowels that should be glued in place. Then wait for the sweat to dry and the marks to leave my face and then roll camera. When youre done, your trunk should resemble this: Then, on top of the masking tape, apply a thick layer of foil.
PS: Carpeting something like this requires a great deal of skill Great for if youre going to do more than one item and it will also be a stronger part and much more resistant to damage. form. We use cookies to make wikiHow great. Sorry guys, but what about safety? You can also use a combination of wood and fiberglass to make subwoofer cabinets that are molded to the area around them. found in fiberglass resin + catalysts like methyl-ethyl keytone (the most walls enough, your enclosure will flex too much and you will both loose
To prevent chemicals from seeping into your cars trunk, place masking tape there. It will take around 2 hours for each layer to dry, depending on the amount of resin you use. fiberglass roller tool (to remove air bubbles), polyester resin (standard fiberglass resin). However, I am planning on purchasing and modifying a scamp fiberglass travel trailer, so i might just have to revisit my fiber glassing days. Just curious if there is any disadvantage to using epoxy? Somewhere around here is my favorite stirring screwdriver, but a throw away stir stick works also. Hand in your geek card. Eric Smith wrote a reply on GoForge - A Renesas FPGA Board. As I was too busy making the form you see Piping of fiberglass increases its life and safe from leaking. walls of your new form. I known fiberglass causes lungs cancer if microfibers reach them. See the video for the trials and tribulations on pulling all of the wrinkles out and how to fasten it down. This step is the most involved I have used the same mix container for a looooong time. is the enclosure's air volume minus the subwoofer's displacement. kelvinA wrote a comment on project log [R] Embedded electrical components. exterior surface of the enclosure, install the subwoofer in the mounting The idea is that the texture helps hide some minor sins. You can use two layers of an old t-shirt to do this job.
How Does The James Webb Telescope Phone Home? The idea is to soak the fleece with the resin until there are no light spots which indicate the presence of air bubbles.
Absolutely! following mini-project will cover the basics of how to create your own Keep it up. Once you are ready, review your fiber glassing technique and proceed to From our tutorial, youll learn how to make a fiberglass subwoofer box in the trunk of your vehicle. You change shirt more than once a week? Its suggested that you do about 4 -5 layers. It will take at least 2 hours for each layer to dry (however, you can use a hair dryer to make it dry faster). Id still prefer a CNC mold and woven glass as opposed to chop fiber or polyester felt.
If you think the trunk lid is bothering you, you can even remove it. Cool Just goes to show you the proper way to do things isnt always the easiest or most accessible. In the next step, you will stretch the lycra (or similar stretchable Magic boxes can be bought with Subwoofers, When you add a subwoofer to your MagicBox order, Discount is taken out of the enclosure. The builders arent looking for long term durability. Read on .. For beginners, you should make Whats also better about that is if something breaks one of the parts you can simply lay up a new one in the mold and itll fit precisely like the original. You can also lay up carbon fiber and epoxy resin, though it helps to have a big autoclave. Does the work release from the mold easy enough? Less guesswork in measuring amounts of resin/curative. If you really like the smell, go with polyester resin, but epoxy has a number of advantages besides being low-odor (you can work indoors). You can also work with carbon fiber with the vacuum bag method. Doesnt you wear suit and gloves to avoid contact with it? By using our website and services, you expressly agree to the placement of our performance, functionality and advertising cookies. I cant stand polyester resin. You just use polyester fleece and resin. The fabric is thin and strong, but does it behave with the resins? The gel-coat layer is only required if you will be painting the (wet spots). % of people told us that this article helped them. BTW, I usually use my belt sander with a real aggressive belt and make the base a lot thinner and flat, or add a bit of contour if needed. I buy my resin from fiberglasssite.com and then write the date on the can. im dont recall an rsx build like that there at any point, though via c7 boards were a little before i got involved in carpcs. series of stilts which you will cut and measure to fit. The Chemicals are dangerous - especially ones questions regarding the procedure, etc, please email us and we will be Place the box back in the trunk, draw a pencil line around the corners, and cut them out. (That and powder coat). Right now we are estimating 4-5 Weeks time to build as we have a surge on orders and are trying our best to keep up with orders in a Pandemic. a workspace which looks similar to that of figure 2. You can alter its thickness, shape, color, and cover, among other things. AVR has updated the project titled Jenny-XJ9. 3?/^_6wZ\ 00Jy,_YIB}Jkg|50/_Dr|=Z4Mc(N/{Uwv;sPn :). Still a good demo for the DIYer who probably doesnt want to go through the learning curve. This article has been viewed 48,059 times. You do have me thinking about making a streamlined body for my quadracycle. Yeah I have been guilty of assuming it will just keep. That is why making a fiberglass subwoofer box appears to be a great idea. Sanding sucks, wear your mask and eye protection and be prepared to get covered in a fine powder. I then cover the entire exposed surface with the good green masking tape. know how the pros make these fiberglass enclosures? Once the resin has fully dried, remove the enclosure from the trunk. Even room temperature cures, given enough cure time, can be totally fine. Hot glue? The fiberglass box has a number of distinct advantages over other forms of enclosures. I also really like the smell, reminds me of a simpler time in 8th grade shop class. The fabric is pulled down over the edges and stretched until no major wrinkles are present. Well, I meant the MDF you stretched the fleece over. The idea is to match your air space as closely as I use Roloc sanding discs in an air sander to remove the huge chunks of filler and then an electric orbital sanderto smooth it out. Personally I spend enough on fresh resin that I didnt want to risk it not setting right. Then, once its cured, just pop it out of the mix container and go again. If you do not understand the basics of fiber glassing, have a look at As far as the type of resin I use, I usually use resins marked as layup or laminating resin, and almost always labeled as a premium resin (though I havent seen that there is an official classification). Thank you for subscribing to the newsletter! Make sure your cars trunk is perfectly clean before you start. That eliminates the need for an autoclave. This part The preferred way to buy resin is to find a source that talks about the freshness of their resin as resin has a shelf life of 3-4 months typically. I buy my mixing cups by the box as well as my stir sticks. And it gives a descent idea of when the part is ready for another layup, although the container of resin will cure a little faster than a big layup. this is the most difficult stage. your wiring and install this bad boy in your ride! 2004 - 2022 Wicked C.A.S.. All rights reserved. Subwoofer stuff needs to be extremely thick and not vibrate or flex. Production houses that do layup fiberglass professionally usually use a applicator that shreds glass fibers and mixes the resin all in one step while blowing it on to the mold. You never cease to amaze me Bil. It becomes part of the speaker.pod. and droop a little more than when it was stapled taught. With proper w/w % of glass to resin and a vacuum bag to properly consolidate the composite.. I wasnt going to get shirty about this we cant all be like Sir David Attenborough and keep to the same outfit for the sake of consistency. Keep up with the latest tech with wikiHow's free Tech Help Newsletter. Mix the resin with a hardener to make it ready to use (the ratio should be specified on the package). I am working on a stich and glue kayak and will have enough left over for my sub box. Custom fiberglass is also good for molding structures like sunken subwoofer panels and the like, where a very irregular surface needs to be turned into an airtight container for the sake of audio quality. I mean, if you have bought the best 12-inch subwoofer for your car, you need to place it in the best enclosure possible. Yeah I mention that to some degree in video, but wherever I go we called the custom resin work Fiberglass (or fibreglass) in general. nozzle to help you get the fiberglass form out of the car. There are times when I feel the need to really make a mess. I learned a lotthanks. -pta]x{tonO+hShT"XUlmz,qvW"E`;b9,h 3gaX=G\fTJz ynq556LN?
Autoclaves are nice, but only really necessary if you are really concerned with weight and want to get the best possible material properties out of the composite. If you mix too much at once, it will dry out before you finish the task. The result will cause the lycra to loosen up slightly Stretching a fabric over a supporting structure will give you class A surfaces w/o the hassle of modelling it in CAD or hand-craping it in automotive clay & making a plaster negative (learnt the stuff from scratch in a industrial / automotive design course). Congrats! I talk about safety in the video.Not just the glass part but care must be taken when sanding bondo. Q3[Y=h3XWmc AVR has updated components for the project titled Jenny-XJ9. wikiHow is a wiki, similar to Wikipedia, which means that many of our articles are co-written by multiple authors. I have a big bottle of hardener lying around and then I also get little bottles with each order. Ive used six-year-old laminating epoxy with no problem. This project will cover the creation of a custom baffle ring and its stilts are joined, join the baffle ring assembly onto Before you start the project, read ALL manufacturer's labels for MDF also makes a good backboard for the pod. To do this, I recommend you use a disposable paint brush and liberally If the resin gets anywhere, it will be nearly impossible to remove, so try your best. The first ring will go along the circumference of the sub. I was always fascinated about how easily you can build structures with fiberglass, but its dangerousness always scared me a bit. The way it was explained when I first got into this was that the polyester fleece sort of melts into the polyester resin. These can be purchased or you can cut them out yourself. The hardener is Methyl Ethyl Ketone Peroxide (MEKP) and is mixed in the ratios of 1-2% MEKP to resin, so for 400ml of resin I usually ad 1.5% or 6ml. Then remove the subwoofer and measure the volume Once your volumes match up, mate the two pieces ensuring an extremely apply the resin. Also be sure to throw on some garbage clothing - it will be ruined no
Yeah lots of MDF out there which swells when it gets damp. I did a dash and center console, the dash I didnt thin acetone and ended up with several wet spots and a lot of areas that didnt penetrate the fleece.
you got me thinking, what about parachute fabric and army surplus? glad to help you on your project.
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