Hi all,
I'm new here and new to the fibreglassing world. I have made a few full wood boxes in the past but I thought it was time I tried glassing.

Started making my fibreglass sub box a few weekends ago. The idea is to have it between the rear strut towers utilising the almost useless space and encroaching only a little into actual boot space. I also have to take into consideration the rear curtain's height so its not mashed up against that.
I taped up the inside of the car where I would be applying the glass. I used masking tape for some then swiftly realized that I had bugger all so used very wide electrical tape. Which actually came off from the car easier than the masking tape as the heat+chemicals in the resin softened the tape. I also tried to use tinfoil but on any acute angles it doesn't work as it just sags. My own fault (beginners mistake)
I applied about 3-5 layers across the whole base. I intended on using glass for the rear of the seats but the acute angle meant it drooped so I cut it off.

Here's some pictures of the base, out of the car. I'd added a few more layers making the base very ridged and inflexible.

More pics to follow. The red line is (roughly) where I have cut.







Cut out the back from MDF and glassed it onto the base. Held in place with short lengths of 15x15mm with hot glue.
I have only done the outside - I'll do the inside once the outside is hard.
Here's a few pics. I'll update with what the temp supports look like.

I know it looks messy for now - I'm sure it'll clean up ok - plus its the back





Here's some of the supports I used to hold the back in place while the glass dried:







And here's one with it in place
The back I will cut to the proper length in due course



And now I'm out of resin - all 4 litres of it hahaha

I did actually stretch material over the whole thing last night and layered some resin down. As the resin was almost setting I added a layer of matter in some of the corners where the angles caused the material to "bunch up". I will use the "smoother" glass finish that the bumpy/bunched material for my outer shape.
I tried to stretch it as much as I could (and it was bloody stretchy) but I've got some odd angles (as you can see from some of the pics) so it was very hard to get the fabric to not bunch up. I'll take more pics tonight.

What I'm worried about is because I've put glass over the bunched up fabric, there is an air bubble between the glass and the bunched up fabric. This would be fine if I was just glassing the outside, but I intend on putting a few layers on the inside as well for strength. Which would mean there's going to be a small air bubble in places. Hopefully it'll be ok.

Ok so no real update. Havent don't any more on it really. I've tried glassing the outside some more but I was too sleepy and kept f***ing it up.

It looks a mess and will require a lot of sanding and a shirt-load more work.
not very happy with how its going - altho it is my first attempt at glassing.





Ok so I bought a cheap palm sander. Does a pretty good job. There's heaps of "lows" I need to fill in. Now that I've got a decent "base" of 1-3 layers (not sure why it varies so much haha) I was thinking of mixing some resin with "bog" to fill in the big lows. Would that be an ok thing to do? That way When I lay another 3 or so layers on top, they'll be being applied to a good shaped surface - where-as if I lay the final layers down now, the shape is all up to s**t.

Ok so here's some photo's. I've not really sanded too hard out - just taken the sheen off. Its hard to see but there are some really big lows/highs. If I use bog mixed with resin, how thick could I do? Some places I could probably go about as deep as 1/2 an inch!

Also - because I was a little to excited, I rushed lining the 2 rings up - so they're not symmetrical. I should have listened to my partner - make them very un-even or make them perfect! OOPS....












I now have an average base which is quite solid. I'll bog (I just bought some fibre-glass bog) all the low spots and get the general shape. Then once I've got the general shape pretty much right, I'll glass over that (for strength) then once I've added 3 or so layers all round I'll sand back to take the shine off, then apply bog/resin to the final product and sand back to prepare it for painting.

so much to do - *sigh* haha

If you've got alot of area to fill have a look into Q-Cel microspheres to add to resin to give it some volume, but without the weight. And its nice and easy to sand!

Good idea. I was thinking about that. That's the powder in a bag that's very fine?

I think I'll just bog+resin the outside once the shape is about right and I'll lay up the inside.

How much does that Q-Cell stuff go for?

Ok next question. When I go to lay up the inside. How the heck am I going to do the sub baffles? Any suggestions on how do do the bits I cant see? I dont fancy sticking my head in the hole and getting my hair full of resin lol

I forget how much I paid for a 1KG box, but its quite a lot and goes a long way since its light.

Any suggestions on laying up the inside? You know, getting to the bits that you cant actually see - like the outside corners of the rings etc?

Is it really that tight? try a makeup mirror or something I guess.

Are you trying to glass the inside or just put resin in there? If its just resin you can pour it in and roll the box around a bit to cover the corners etc.

I've layed up as much as I could around the inside of the rings. It is pretty tight but worked out ok. I put the ring that I was working on, flat on the bench, while the other ring overhung the bench. I added some "stuff" on it so it wouldn't fall over - then poked my arms in and started throwing resin around - and matting
I'll be hoping to finish laying up the inside as much as I can tonight. Pics to come

Ok so the inside of the box is all done as far as thickness goes. Now I've got to make sure the corners are fully sealed and strengthened.

I remembered last night that I have yet to cut a slot for the divider to go into and glass that in place. Dam I thought I was so close

Rather than cut a slot for it to go in, I would cut the divider and then reassemble it inside the box. The integrity of the box is more important than the strength of the divider IMO.

Ah well - too late now as I cut a slot hehe.




And here's one with the subs sitting in place and the box in the car.



Not much to do now but bog and sand and sand and sand x100 hehe

Looks good lots of sanding to go as you said!

Tell me about it. I'll have a bash tonight with the fibrebog and a sander and see how I get on.

Here's with the subs screwed in place. They lined up "ok":

Thats pretty good for a first attempt mate.

Thanks

Hopefully it sounds ok. It should be loud enough as it's not in a sedan, so hopefully it's tight too

Hopefully!

In all seriousness, looks better than my first attempt... Good job!!

haha - not that kind of tight! Altho it is a VERY tight fit - I have to REALLY push it into place.

Just got me some lomu 6.5 components

Little bit of an update - started making the false floor. Big empty bit on the right is where the battery sits:

Lid down:



Top lid open - showing where the amps would be:




Amp rack liften - allowing access to spare wheel:

oh do i wish i could do that.......
subs/amps and spare tyre

looking good mate keep up the work

Cheers

There isn't a huge amount of room however - but the boot is quite deep - it has to be as its not very high.

Still a LOT of work to do - both sub box and floor have basic shape now - just got to smooth it all out