New boot install - flaming expected.

**BazzaAlpine** · 5-2-07, 15:42

Well that was it. I finally got fed up of the sub box sliding round the boot and decided to do my own install (even if very basic). Only hitch, I was going to have to use fiberglass. Got the dimentions and even planned it all out in a CAD program. This was bigger than anything I had tried before but I was confident....Time to get the wood.

OK bank holiday weekend was not the best time to get the bits. 3 DIY stores later and we finally found the MDF. 4mm thicker than I had planned but it would do.

Got it all home (that was fun in a sports coupe that still had twin 10" subs in it) and marked it all out.

Cut out the base and checked it to the size of the boot...spot on. The confidence was getting higher

Cut the sides and backs for the sub enclosures and glued them in place.

Now this is where things start falling to bits...literally. I go to trail fit the base back in the boot and wouldn't you know it, it won't go in. The fing gap for the boot lid is not wide enough to tilt the base in with the sides. No prob, the rear seats go down so I'll put it in that way.....Goes through the door ok but hang on, the parcel shelf curves down 2 inches too far. Time for a rethink and as I take the base out the back...all the sides fall off *slaps head*

In the end I decided to cut the base into 3, the 2 sub enclosures and the centre section where the cd changer and amp will be going. Steaming ahead now with the first sub mount on.

Place it all in the boot and I've discovered another snag. I hadn't given enough space for the CD changer. Brackets fine but with the connectors nope. Looks like I'm leaving that till last.
Meantime I've put the cover on the right side sub box ready for some fibreglass resin and almost put a screwdriver through a knuckle on my hand trying to get some screws into a disk to keep it all tight. Revenge was sweet when I reached for the hammer.

Added the resin and couldn't see any sagging in the cloth so still looking good. Go to clean the tub and brush I was using and I put in white spirits instead of thinners. I have learned an interesting new fact...White spirits helps fibreglass resin set 10 times faster at the cost of getting seriously hot. So hot that the piece I took out of the tub was smoking. Shopping for new brush and thinners tomorrow.

19-04-07
Got the brush and some hamerite stuff that was the only thing that said thinners on it. Got back home in time to put a second layer of resin on the box and yes, the brush is now clean.

29-04-07
Got the left side box covered and a layer of resin put on last weekend. For some reason this one's proving to be slightly more of a pain. To the point my knife blade snapped and went straight through the cloth. Luckily the resin was completely dry so the only thing I need to do is patch up the slash with a bit more resin before I put the fibreglass on. I also have a bit of a play with the centre section and the CD changer is now fixed to the top and used some cardboard to make a nice curved enclosure for it. Considering how much of a bodge job it was it's actually come out better than expected.

This weekend has been busy and got the sunburn to prove it. All three parts are now fibreglassed and sanded though the middle could do with a little more of the fibreglass trimmed off.

I've put a bit of filler on the tops of the boxes to see how easy it's going to be to get the finish I want and all I'll say is I think I'm going to need plenty
of sand paper. I also got the paint today: Decided on a purple base with yellow/gold flip. Might have to think on something for the lighting in the boot to show it off better though.

01-05-07
Put more of the filler over both sub boxes. Probably not the best idea to do it indoors but I needed the light. Talk about high as a kite.

Will save the sanding for the weekend I think.

Let the flaming commence......

mogsy · 5-2-07, 15:56

hats off to you mate ive been thinking of enclosing my sub since ive put it in the car i probably would have had a go by now if it wasnt for this damn lazyness

**supersparky** · 5-3-07, 13:04

engines, electrics, ICE installs A/C no probs.

I would'nt even attempt to make what you have done hats off.

keep the progress reports coming.

gareth

klzeman · 5-3-07, 15:35

What kind of person would flame you for doing a smashing job on this looks really good and I wish I had your skills

I have one of those bose sub systems in mine but its not pretty to look at and could do with a bit more power its sat in my closet at the moment as half the car is in bits being worked on now Im not sure I want to put it back in

wonder how much it is worth complete with head units radio/tape and a 2nd din sized cd player to go with it

**noonespecial** · 5-3-07, 15:39

ahhh.. I see the sun makes other think the same.. doing the same, but different... nice work.. did you calculate the area in the boxes or just guess?

Off to get my bits tomorrow ..

**BazzaAlpine** · 5-3-07, 16:22

Quote:

Originally Posted by noonespecial

ahhh.. I see the sun makes other think the same.. doing the same, but different... nice work.. did you calculate the area in the boxes or just guess?

Off to get my bits tomorrow ..

To be honest I looked at the old, standard box, and thought 'Yeah that'll do'.

Thanks for the comments. I'll get an other update done at the weekend. Watch this space......

**BazzaAlpine** · 5-9-07, 17:35

06-05-07
Well after a weekend of sanding I think I'm ready for the undercoat. Actually had to take off some of the filler at one point as I it hadn't set. Must have not used enough hardener

The centre section was a real pig to do mostly because I had to keep the CD changer in (it's glued in because I didn't have room for the brackets and, no, I couldn't leave it till after I'd done everything because it's the only thing keeping the centre at the right angle).

08-05-07
2 coats of primer on now and looking good if I do say so myself. Rubbed it down with wet and dry between coats and I'll probably rub this coat down a bit too then put on the final coat of primer.

**BazzaAlpine** · 5-19-07, 15:38

19-05-07
Oh what fun I've been having. In the little dry time there was last weekend I managed to get the Purple coat of paint on all 3 sections then decided to have a go at the top coat of flip yellow (though it looks more silver to be honest). Disaster. The tin definitely wasn't spraying properly so bubbles and all sorts appeared

Quick call to Halfords during the week and they replaced the tin (even gave me 20ml extra which I thought was kind of them). This weekend has started much better even though I had to sand down the old coat of paint and put some fresh purple on. Whilst that was drying on 2 sections I managed to get the flip coat on the 3rd. Must say it is absolutely vital when spraying a paint like this to make sure you do not change direction!

As the weather was so nice all day I even managed to get the other 2 dry enough to sand down and paint.

Hopefully tomorrow will be nice enough I can either put a second layer of the flip on or even just go straight for the lacquer.

**rasheedn** · 5-19-07, 20:13

looks good

but why??? i only changed the stock speakers and it was more than enough
:S

**BazzaAlpine** · 5-21-07, 14:56

I think in a word...Bass

lots of it. Also to see if I could even do it.

Finished product:

**Tex_Mx** · 5-23-07, 5:08

First Class.

Excellent job mate and a good write up as well.Better than some old sub box slidng around any day.

Now time to get the drill out and put some leds flashing around to make it sparkle.

Roy

5-2-07, 15:42	#1 (permalink)
BazzaAlpine Join Date: May 2005 Location: St Ives, UK Age: 37 iTrader: (0)	New boot install - flaming expected. Well that was it. I finally got fed up of the sub box sliding round the boot and decided to do my own install (even if very basic). Only hitch, I was going to have to use fiberglass. Got the dimentions and even planned it all out in a CAD program. This was bigger than anything I had tried before but I was confident....Time to get the wood. OK bank holiday weekend was not the best time to get the bits. 3 DIY stores later and we finally found the MDF. 4mm thicker than I had planned but it would do. Got it all home (that was fun in a sports coupe that still had twin 10" subs in it) and marked it all out. Cut out the base and checked it to the size of the boot...spot on. The confidence was getting higher Cut the sides and backs for the sub enclosures and glued them in place. Now this is where things start falling to bits...literally. I go to trail fit the base back in the boot and wouldn't you know it, it won't go in. The fing gap for the boot lid is not wide enough to tilt the base in with the sides. No prob, the rear seats go down so I'll put it in that way.....Goes through the door ok but hang on, the parcel shelf curves down 2 inches too far. Time for a rethink and as I take the base out the back...all the sides fall off slaps head In the end I decided to cut the base into 3, the 2 sub enclosures and the centre section where the cd changer and amp will be going. Steaming ahead now with the first sub mount on. Place it all in the boot and I've discovered another snag. I hadn't given enough space for the CD changer. Brackets fine but with the connectors nope. Looks like I'm leaving that till last. Meantime I've put the cover on the right side sub box ready for some fibreglass resin and almost put a screwdriver through a knuckle on my hand trying to get some screws into a disk to keep it all tight. Revenge was sweet when I reached for the hammer. Added the resin and couldn't see any sagging in the cloth so still looking good. Go to clean the tub and brush I was using and I put in white spirits instead of thinners. I have learned an interesting new fact...White spirits helps fibreglass resin set 10 times faster at the cost of getting seriously hot. So hot that the piece I took out of the tub was smoking. Shopping for new brush and thinners tomorrow. 19-04-07 Got the brush and some hamerite stuff that was the only thing that said thinners on it. Got back home in time to put a second layer of resin on the box and yes, the brush is now clean. 29-04-07 Got the left side box covered and a layer of resin put on last weekend. For some reason this one's proving to be slightly more of a pain. To the point my knife blade snapped and went straight through the cloth. Luckily the resin was completely dry so the only thing I need to do is patch up the slash with a bit more resin before I put the fibreglass on. I also have a bit of a play with the centre section and the CD changer is now fixed to the top and used some cardboard to make a nice curved enclosure for it. Considering how much of a bodge job it was it's actually come out better than expected. This weekend has been busy and got the sunburn to prove it. All three parts are now fibreglassed and sanded though the middle could do with a little more of the fibreglass trimmed off. I've put a bit of filler on the tops of the boxes to see how easy it's going to be to get the finish I want and all I'll say is I think I'm going to need plenty of sand paper. I also got the paint today: Decided on a purple base with yellow/gold flip. Might have to think on something for the lighting in the boot to show it off better though. 01-05-07 Put more of the filler over both sub boxes. Probably not the best idea to do it indoors but I needed the light. Talk about high as a kite. Will save the sanding for the weekend I think. Let the flaming commence......

5-3-07, 13:04	#3 (permalink)
supersparky Join Date: Jan 2007 Location: shropshire, UK Age: 33 iTrader: (0)	engines, electrics, ICE installs A/C no probs. I would'nt even attempt to make what you have done hats off. keep the progress reports coming. gareth
	back from the land of speed traps, barbies, kangaroos's and crims

5-3-07, 15:39	#5 (permalink)
noonespecial Join Date: Aug 2004 Location: UK, UK iTrader: (0)	ahhh.. I see the sun makes other think the same.. doing the same, but different... nice work.. did you calculate the area in the boxes or just guess? Off to get my bits tomorrow ..
	Noonespecial has left the building... thanks n so long for all the fish....

5-9-07, 17:35	#7 (permalink)
BazzaAlpine Join Date: May 2005 Location: St Ives, UK Age: 37 iTrader: (0)	Update 06-05-07 Well after a weekend of sanding I think I'm ready for the undercoat. Actually had to take off some of the filler at one point as I it hadn't set. Must have not used enough hardener The centre section was a real pig to do mostly because I had to keep the CD changer in (it's glued in because I didn't have room for the brackets and, no, I couldn't leave it till after I'd done everything because it's the only thing keeping the centre at the right angle). 08-05-07 2 coats of primer on now and looking good if I do say so myself. Rubbed it down with wet and dry between coats and I'll probably rub this coat down a bit too then put on the final coat of primer. Last edited by BazzaAlpine : 5-19-07 at 15:40.

5-19-07, 20:13	#9 (permalink)
rasheedn Racing for team Palestine Join Date: Apr 2005 Location: Jerusalem, "Palestine" Age: 24 iTrader: (0)	looks good but why??? i only changed the stock speakers and it was more than enough :S
	RUSHING RASHEEEEEED 2004 Subaru Impreza WRX STI SS brake lines,carpc,remap, F&R antiroll bars, anti-lift kit, SS exhaust system, (VF 37 Twin scroll turbo equal length headers, 50/50 meth injection and RCE Tarmac 2 Coilovers

5-2-07, 15:56	#2 (permalink)
mogsy Join Date: Dec 2006 Location: newport s wales, UK Age: 33 iTrader: (0)	hats off to you mate ive been thinking of enclosing my sub since ive put it in the car i probably would have had a go by now if it wasnt for this damn lazyness

5-3-07, 15:35	#4 (permalink)
klzeman Join Date: Apr 2007 Location: Oxfordshire, UK iTrader: (0)	What kind of person would flame you for doing a smashing job on this looks really good and I wish I had your skills I have one of those bose sub systems in mine but its not pretty to look at and could do with a bit more power its sat in my closet at the moment as half the car is in bits being worked on now Im not sure I want to put it back in wonder how much it is worth complete with head units radio/tape and a 2nd din sized cd player to go with it

5-19-07, 15:38	#8 (permalink)
BazzaAlpine Join Date: May 2005 Location: St Ives, UK Age: 37 iTrader: (0)	19-05-07 Oh what fun I've been having. In the little dry time there was last weekend I managed to get the Purple coat of paint on all 3 sections then decided to have a go at the top coat of flip yellow (though it looks more silver to be honest). Disaster. The tin definitely wasn't spraying properly so bubbles and all sorts appeared Quick call to Halfords during the week and they replaced the tin (even gave me 20ml extra which I thought was kind of them). This weekend has started much better even though I had to sand down the old coat of paint and put some fresh purple on. Whilst that was drying on 2 sections I managed to get the flip coat on the 3rd. Must say it is absolutely vital when spraying a paint like this to make sure you do not change direction! As the weather was so nice all day I even managed to get the other 2 dry enough to sand down and paint. Hopefully tomorrow will be nice enough I can either put a second layer of the flip on or even just go straight for the lacquer.

5-21-07, 14:56	#10 (permalink)
BazzaAlpine Join Date: May 2005 Location: St Ives, UK Age: 37 iTrader: (0)	I think in a word...Bass lots of it. Also to see if I could even do it. Finished product:

5-23-07, 5:08	#11 (permalink)
Tex_Mx Join Date: Jul 2004 Location: , Cornwall iTrader: (0)	First Class. Excellent job mate and a good write up as well.Better than some old sub box slidng around any day. Now time to get the drill out and put some leds flashing around to make it sparkle. Roy