Custom Stereo Trunk Enclosure (NEON)
We are only partially finished with the enclosure but you can get the idea of what this will look like from the pictures below.
We built a new sub-floor to make it even with the full size spare tire. Picture on the left shows how it is built as a two-piece unit. Other picture shows both sides in there with the height of the floor being level with the tire. We still need to carpet the floor - pictures of this as soon as we complete it.
Cut the cardboard as a template for the one box enclosure. The plan is to make both of them look like volcano's with the 10" subs coming out from the center. Picture on the right shows the MDF board cutout as the framework for the custom enclosure.
Don't want fiberglass on the carpet, as you will never be able to get it off. So, put down some aluminum foil and tape the seams. From there, add the matting to form the back fiberglass enclosure.
Here’s a pic of putting on the Fiberglass resin. Just remember to add enough harder to the resin or you'll need a hair dryer to speed up the molding process (hint hint).
Partial finished product. The cup was used to keep the enclosure from collapsing. Matt will add more fiberglass strips to seal the box more. He had mentioned about 3-4 layers of coatings.
Total amount of time into project: 6 hours
I'm going to show you how the actual 'volcano' part. The following pictures will run you through what is needed and how to build this enclosure.
After the enclosure is dried, you need to get a ring cut out with the legs to raise it off of the main board. We actually taped it and then glued. From there we then used Fiberglass strips to strengthen the raised part. Make up about 3 more batches of resin and poured it into the enclosure to seal the rest of the box. Then add some material across the top of the enclosure to form the 'volcano'.
After wrapping the enclosure, Apply a coat of fiberglass resin to the outside of the matting. Once its cured you cut out he hole for the subwoofer.
The two above photos show the enclosure on the drivers side with the sub-floor.
Phase 1 complete
Total time to complete phase 1 approximately 20 hours.
PHASE 2
The main difference in phase 2 was the addition of another volcano for the amp. Don't have any build up pictures of this volcano, only final pictures. Now that this is complete, the amp has been setup for 2-channel and the sub's were bridged.
For Phase 3, the plan is to put in some 5.25" Boston Acoustics co-axial speaker (w/ mini tweeters) up in the doors and dash. Then switch the amp over to 4-channel to run both the subs and co-axials.
Phase 2 took us approximately 6 hours to complete including wiring up the amp.
ramzees87