Building Custom Box in Enclosed Space?

**Dr.jinG** · 01-23-2007, 10:51 AM

I have a small space (VERY small) under my rear seats that I'm planning on building custom boxes for 6" round speakers (that's all the space I've got). What would be the recommended method for building a box to fit the space snugly, and be a good fiberglass job?

I was thinking one of two ways:

1) Box in the area with tape/wood/plastic sheet, and lay in glass to build it up (don't get a really good glass box out of this, though, I think), and possibly expand a balloon into the space to hold things in place as the first layer or two cures.

2) Create a plug with expanding foam and a plastic bag, remove the plug, cut to shape, build box around plug, remove plug and seal the box.

Any other ideas? I'm sure this has been done many times but I'm not even sure what search terms to use to find them.

Thanks!

**GoHybrid** · 01-23-2007, 11:02 AM

your first idea is the more conventional method. It will adhere perfectly to the contours of the space if you use good technique in laying the fiberglass down. This means not trying to cover the whole thing in one sheet, cutting/tearing the fabric to better conform to the contours, as well as using a roller to consolidate the layers and press out any air bubbles. This also improves saturation.

the second idea is intriguing. i would suggest going to a packing store and getting one of those bags with the expanding foam inside it. this might give you a more rigid structure to work with and contain your mess. Keep us posted on what you decide!

**Dr.jinG** · 01-23-2007, 01:33 PM

Thank you, GoHybrid. I've done a little glass work, but hadn't considered the use of a roller. Great idea! I'm assuming a hard rubber roller is the ideal tool. I'll go with this plan, instead of the plug idea, because it will conform to the space the best. Using the roller will prevent poor adhesion (which is what I was afraid of: Too much resin, not enough cloth, and too much gap between them.).

**turbocad6** · 01-23-2007, 02:28 PM

yeah,

... also, tin foil is usually best for lining everything for the glass cause it won't stick to it, tape & cardboard can get messy, just layer it with tinfoil after the tape & cardboard & it'll pop right out...

**Dr.jinG** · 01-23-2007, 02:32 PM

Will do. Thanks, turbocad6 (btw, does that mean you're an exceptionally fast letch?)...

**turbocad6** · 01-23-2007, 02:38 PM

turbocad6= a 6 cylinder turbocharged engine in a cadillac

**GoHybrid** · 01-23-2007, 03:34 PM

dr.jing, there is actually a specific roller tool made for fiberglass, such as this. The rollers are ribbed which helps the bubbles break through the surface rather than just being pushed around underneath. These are cheap and in fact quite reusable if you have acetone handy to clean your tools before the resin kicks.

**Dr.jinG** · 01-24-2007, 12:47 AM

Awesome! Being back in the land of Tap Plastics, these will be easy for me to get. Little bit of a drive, but cheaper than shipping!

Thanks for the help, everyone. I'll post when I do the job...

**scott_fx** · 01-24-2007, 06:16 AM

your car rocks btw...

ok back to the help

**Dr.jinG** · 01-28-2007, 02:33 PM

Thanks, again, everyone. Sorry I've been away, but I haven't used my home computer in a while, and I don't recall my password for this site, so I can't log on with my work computer... Darnit.

Cheers!