HOW-TO: Build a custom subwoofer enclosure for a 'vert.

[$100T2]

DISCLAIMER:

This is how I did it. Maybe you'll do it differently. Maybe you have better skills than I do. Maybe you don't have the skills I have. Maybe you have better tools. Maybe you don't. Bottom line, this is how I did the enclosure for my 'vert, and there ya go. I'm not responsible for you fucking up your car if you try to duplicate this. That's on you.

Tool list:

Circular saw
Jigsaw
4 foot straightedge/ruler
Tape measure
Pencil
Trimmer/Router
Drill
Compass

All my stuff is Ryobi One+ 18 volt. It's a nice system to have. Cordless rules. The only corded tool I used was my circular saw.

The story:

My 'vert originally had a pair of 10" Kenwood subs in a pre-fab box. It sucked for several reasons: It slid around constantly, it killed what little trunk space I had, and it looked like shit.

I've been brainstorming how to do an enclosure for quite some time. I've watched a LOT of Overhaulin', Pimp My Shitbox, err, Ride, Rides, etc. I also own a DVD set of "how to do fiberglass enclosures", so I have lots of ideas. (Anyone wants copies of those, let me know. I'll do 'em for you cheap.)

My trunk is missing almost all the plastics, so one bonus of this is that I don't really have to worry about the plastics now.

The first thing I did was cut a back piece:
http://i15.photobucket.com/albums/a353/100T2x3/100_1746.jpg

Then I cut a bottom piece. Note the hole trimmed out on the right to allow for the piece where the gas filler goes into the gas tank.
http://i15.photobucket.com/albums/a353/100T2x3/100_1747.jpg

Then, I cut the pieces into three parts. The center piece is measured off my amplifier, the other two pieces are equal to each other for the subs. Why? Because I made it as big as I could, meaning it would leave me maximum volume and maximum trunk space. It will also be a lot more difficult to steal once it's assembled in the car and bolted back into one piece.
http://i15.photobucket.com/albums/a353/100T2x3/100_1748.jpg

Here's a quick mock-up in the trunk after I made some side pieces.
http://i15.photobucket.com/albums/a353/100T2x3/100_1749.jpg

Here's a test fit of the amp:
http://i15.photobucket.com/albums/a353/100T2x3/100_1750.jpg

Here's the outsides built, and the subs just laid in place to give an idea what it will look like:
http://i15.photobucket.com/albums/a353/100T2x3/100_1752.jpg

Then I cut out rings to hold the subs. Because the front of the enclosure will be made from fiberglass, I just made rings.
http://i15.photobucket.com/albums/a353/100T2x3/100_1754.jpg

I then used my trimmer/router to rabbit the edges of the rings. This is the rabbit head:
http://i15.photobucket.com/albums/a353/100T2x3/100_1755.jpg

This is the groove that was made:
http://i15.photobucket.com/albums/a353/100T2x3/100_1756.jpg

This is all for today. I'll post the rest tomorrow.

[$100T2]

Alright, little update. I did this during the Magic's ass-whooping of the Cavs.

Basically, I took a hot glue gun and some wooden dowels I had around, cut them to the length I wanted, and glued the rings in place.

http://i15.photobucket.com/albums/a353/100T2x3/100_1762.jpg

http://i15.photobucket.com/albums/a353/100T2x3/100_1758.jpg

Mayhem says, "I like it, I love it, I want some more of it!"
http://i15.photobucket.com/albums/a353/100T2x3/100_1760.jpg

http://i15.photobucket.com/albums/a353/100T2x3/100_1759.jpg

That's all I can do tonight. I need to go buy some fleece to cover them, then 'glass 'em in, and that's that.

[JustJeff]

Nice write up. I use my trunk too much to loose it to a pair of subs. I built a fiberglass enclosure in the driver side well, behind the seats. I was using a Boston Pro 8 and a JL Slash amp. Till my JL amp stopped powering up.

[$100T2]

I was going to do the subs behind the seats, but didn't feel like it. I'm not going to lose the trunk to the subs, there will still be some usable space, especially since the bottom board will cover the spare tire well.

[JShiz]

Ported box?

[$100T2]

No, sealed.

[JShiz]

Square footage?

[TitaniumTT]

Looks good so far. Why the rabbit? I'm a little confused a litte on the need for that.

Only advice I can give about the fleece and the MDF, make sure you wet out the MDF REALLY well and when it starts to kick wet out the fleece and the put it on. You get a much bond between dissimilar materials like that.

[$100T2]

Looks good so far. Why the rabbit? I'm a little confused a litte on the need for that.

Helps give a flush mount for when I staple the fleece to the MDF.

[TitaniumTT]

Watch out for this guy, he's a thinker. :icon_tup:

What are you using for epoxy? Plan on using any additives? I had good success using High Density Adhesive Filler mixed a little runny to fill some of the voids caused by the differences in hieght between the fleece material and the MDF

[$100T2]

I actually used a can of "fiberglass resin jelly" rather than just regular resin because the regular resin was sold out. Gave a bit of additional thickness to the fleece. I coated it inside and out. After it cured, I used bondo-hair to thicken it up further, then sanded it mostly smooth. Then I did two coats of bondo, sanded in between to try to cover up major dips. Because I'm going to cover them with some sort of fabric or vinyl, I didn't really sweat getting them perfect. I'm probably going to modify the boxes a little bit for the subs to push them back a bit. They are a very, very tight fit.


Like I said, cheesy paint and unfinished because I'm thinking of making some slight modifications before I cover them for good.

Here's how it turned out... The two 12s are actually a little TOO loud, so at least I don't need to run them full bore:

http://i15.photobucket.com/albums/a353/100T2x3/100_1765.jpg
http://i15.photobucket.com/albums/a353/100T2x3/100_1764.jpg

[yeti]

hm, I'm trying to figure out if you have more airspace then my setup.. I have posted pictures somewhere before and I didn't feel like thread jacking so to speak to show it. But I can show pictures if you want. BTW mine was under the wind deflector.