Igor Kromin |   Consultant. Coder. Blogger. Tinkerer. Gamer.

NOTE: This article is 3 years or older so its information may no longer be relevant. Read on at your own discretion! Comments for this article have automatically been locked, refer to the FAQ for more details.
This is a follow up post from Part 2 where I finished the floor and amplifier fitting, in this post I describe the construction of the subwoofer enclosure.

The plan for building this enclosure was to make a part MDF, part fibreglass box with front and rear sections made out of MDF, an MDF frame and the rest fibreglass. In hindsight I should have used MDF for all sides and just reinforced with fibreglass inside.

The first thing I did was make a template for the front face out of cardboard.
IMG_0724.JPG




Once the template was done, I cut the 18mm MDF front section out, measured out the hole for the subwoofer and cut that out too.
IMG_0727.JPG

IMG_0729.JPG


Then it was time for a test fit.
IMG_0731.JPG


I measured up and cut the rear section to size out of 12mm MDF. The bit of MDF screwed into it is just to keep it in place while marking out the sides that are going to make up the frame of the box.
IMG_0734.JPG


With the side sections marked out and cut, they're attached to the rear.
IMG_0736.JPG


At this point it was time to start using the fibreglass and resin so some precautions were in hand...
IMG_0801.JPG

IMG_0798.JPG


The bottom of the box was made out of scraps, so came in 3 sections, the middle one was fibreglassed in right inside the boot itself, with a plastic sheet covering the boot so it didn't stick.
IMG_0777.JPG


Later on I added the other two bits and more fibreglass all around the edges.
IMG_0781.JPG


Test fitting the subwoofer, there's plenty of space there.
IMG_0783.JPG


The next part was a bit of a challenge, the top section. This had to be custom fit to the shape of the boot, it had curves and couldn't be easily made out of MDF. The solution, some stockings stretched over the box, resin spread over them, then covered with plastic and placed into the boot to match exactly where the box will ultimately sit. This gives the exact shape we are after.
IMG_0785.JPG

IMG_0786.JPG

IMG_0787.JPG


Once dry and the plastic removed, it was more or less what I wanted, albeit a little rough, but I could fix this later on as it needed many more layers of fibreglass before it was ready.
IMG_0792.JPG


Same treatment was done for the sides.
IMG_0793.JPG

IMG_0801.JPG


Eventually I added all the needed layers of fibreglass and sanded it down to the right shape.
IMG_0795.JPG


The top needed more work to reinforce it. The bubbles seen there aren't important because the resin was added on the inside of the box, the outside was acting as a frame only.
IMG_0799.JPG


To get the sides straight, I mixed the Aeorsil with the resin and let gravity do the work by pouring it on the side and letting it settle.
IMG_0813.JPG


The aerosil mix went on top of the enclosure too. I've cut the speaker terminal connectors in at this point as well.
IMG_0817.JPG


The next post deals with some internals of the enclosure and carpeting, plus the final finish for the install.

Update: Part 4 is here.

-i

Skip down to comments...
Hope you found this post useful...

...so please read on! I love writing articles that provide beneficial information, tips and examples to my readers. All information on my blog is provided free of charge and I encourage you to share it as you wish. There is a small favour I ask in return however - engage in comments below, provide feedback, and if you see mistakes let me know.

If you want to show additional support and help me pay for web hosting and domain name registration, donations, no matter how small, are always welcome!

Use of any information contained in this blog post/article is subject to this disclaimer.
 
comments powered by Disqus
Other posts you may like...