Things you will need:
Approximately 1.5L of fibreglass resin + 25ml of catalyst
Fibreglass matting - about 1.5 sq metres
9mm mdf sheet (big enough for rings + pod frame)
Vinyl - approximately 1.5 sq metres (i bought 1metre from spotlight- its 1.5m wide)
Fleece material to cover pods.
Pva glue
Car Body filler
Sandpaper
Contact adhesive (about 300ml)
A few cheap paintbrush's (will end up in the bin) + disposable gloves
Appropriate wood working tools
Staple Gun
Hairdryer / heat gun
The fibreglassing materials can be bought from most big hardware stores and boating places. The rest of the materials i bought from bunnings.
Step 1:
Mark out the shape you want the pods and the MDF rings that will be used to mount the speakers and grill into. Cut these out using a jigsaw / router.
Step 2:
As my pods are full door length i needed to create a curve at the speaker end to sit flush onto the door trim. I did this by putting aluminium foil on the door trim where i needed to fibreglass and placed the backing peice i had cut out into position. Following the manufacturers directions, mixed some fibreglass resin up and applied fibreglass / resin to form the curve (i will show this process later (when fibreglassing the actual pods in step 7 )
Pictures:
http://astro.mine.nu/podconstruction/DSC_1796.jpg
http://astro.mine.nu/podconstruction/DSC_1797.jpg
http://astro.mine.nu/podconstruction/DSC_1812.jpg
Step 3:
Cut out the mdf rings and i nailed them all together to sand (so they are all the same!) Then glued the one the speaker was to be mounted into together with the other 2 smaller rings (can be made with 1 ring but i didnt have any thicker MDF lying around) so i could "flush mount" them. This is done using PVA glue.
Pictures:
http://astro.mine.nu/podconstruction/DSC_1800.JPG
http://astro.mine.nu/podconstruction/DSC_1803.jpg
http://astro.mine.nu/podconstruction/DSC_1805.jpg
http://astro.mine.nu/podconstruction/DSC_1806.jpg
http://astro.mine.nu/podconstruction/DSC_1807.jpg
Step 4:
Took them to the car and held them into their position - just to make sure it was all going to fit and the angles at which i wanted the speakers to aim - and that the magnet of the speaker will line up with the existing hole (save me cutting more). Once this is done, cut some small "legs" out of some scrap wood and fix to the mdf rings at the desired angle. I used small nails and glue to hold them into position - they will need to be strong, but not overboard. Before securing the rings down, cut out a hole in the backing peice for the magnet of the driver to fit through.
Pictures:
http://astro.mine.nu/podconstruction/DSC_1816.jpg
http://astro.mine.nu/podconstruction/DSC_1818.JPG
Step 5:
As i wanted a more curved finish as an end product, i used a foam mould the entire length of the pod. NOTE: Normal foam will not work! - you will have to use polyurethane foam which is quite expensive (this step is not required depending on how you want the final product to look). Using sand paper i shaped the foam to how i wanted it and held it into place with some masking tape (once the fleece is on it will hold it in place more firmly)
Pictures:
http://astro.mine.nu/podconstruction/DSC_1820.jpg
http://astro.mine.nu/podconstruction/DSC_1822.jpg
Step 6:
Now that i have got the desired shape i wanted, i need to apply some fleecy material to get the final shape / something to fibreglass onto. This is stretched firmly over the entire mould and stapled to the back of the backing peice. Then stapled down into the mdf rings. Once in position, cut off the excess material overhanging at the back. (i used a pair of old tracksuit pants
)
Pictures:
http://astro.mine.nu/podconstruction/DSC_1823.jpg
Step 7:
Mix up more resin. To do this follow the manufacturers guidelines - its 1% catalyst. To make it set quicker you can add more catalyst, but only experience will allow you to judge how long its going to take you / how much catalyst you add - its no good having a heap of resin thats set before you can apply it! (i was using approximately 1.5 times what the manufacturer stated) - Use smaller batches and make more of them.
When mixing it, close enough is good enough - i was using a coke can to measure the resin as its a pain in the ass to clean without acetone (might also want to get some if you spill it / get it on yourself). I just used a measuring beaker to measure the cataylst (cleans more easily). - stir the mixture thoroughly to make sure its mixed well - it should change colours slightly (from a bluey colour to a more green colour). USE GLOVES - resin is an absolute pain to get off your hands.
Pictures:
http://astro.mine.nu/podconstruction/DSC_1808.jpg
http://astro.mine.nu/podconstruction/DSC_1831.JPG
Once the resin is mixed, "paint" on a generous amount onto the fleecy material. It will soak up a fair bit but make sure its applied right to the edges of the backing peice and MDF rings (the edge where the speaker will go in) as this is what holds the fibreglass in place (it soaks into the wood and "sticks" it all on.
More Pictures:
http://astro.mine.nu/podconstruction/DSC_1833.JPG
Step 8:
Apply the Fibreglass matting in smaller more manageable pieces, using a dabbing motion rather than a painting one - the matting will go clear when enough resin is applied. Apply 2 or so layers all over the pod right upto the edges. You will most likely need to make a few batches of resin. Allow to dry once finished (overnight/few hours depending on how much resin was used).
Pictures:
http://astro.mine.nu/podconstruction/DSC_1834.JPG
http://astro.mine.nu/podconstruction/DSC_1836.JPG
Step 9:
Sand off / Cut excess matting away from the edges and inside the rings. Use a face mask to advoid breathing the dust in and wear glasses to keep it outa your eyes. Give it a quick once over with a sander.
Pictures:
http://astro.mine.nu/podconstruction/DSC_1845.JPG
Step 10:
Mix up the bog (follow the manufacturers instructions, again the more hardener / catalyst the faster it will set) and apply to the pod and allow to dry, then sand off (you will be left with a nice smooth surface without the minor blemishes that the fibreglass will leave)
Pictures:
http://astro.mine.nu/podconstruction/DSC_1855.JPG
http://astro.mine.nu/podconstruction/DSC_1879.JPG
Step 11:
Cut the vinyl / covering material to the approximate size and allow some overhang. Apply contact adhesive to both the pod and the back of the vinyl.
Pictures:
http://astro.mine.nu/podconstruction/DSC_1880.JPG
http://astro.mine.nu/podconstruction/DSC_1881.JPG
Then carefully heat and stretch the material over the pod, stapleing it into the backing peice as you go (make sure you do not get ripples / air bubbles as it will look poor). - Work in small sections.
Step 12:
Cut off the excess material / vinyl and fix to the door trim (screwed from behind). Put in speaker and grill and return the door trim to the door..
Finished product:
http://astro.mine.nu/podconstruction/DSC_1882.JPG
http://astro.mine.nu/podconstruction/DSC_1883.JPG
http://astro.mine.nu/podconstruction/DSC_1884.JPG
