- 1). Cut five equally sized pieces of mdf, according the the sub manufacturers specifications.
- 2). Glue the mdf together to form a cube with one open end.
- 3). Put a screw in each of the four corners of each side of the frame for added support.
- 4). Cut the dowel rods so that they protrude from the box exactly as far as you want them to. Each dowel rod will sit on the floor of the box, and come out the open end of the cube so that it looks as if the speaker is protruding from the enclosure.
- 5). Place the dowel rods where you would like them, and ensure that your speaker fits between them. Adjust the dowel rods so that your speaker fits where you want it to, and then trace a line around the bottom of each one.
- 6). Add a dab of glue to the center of each of the dowel rod circles. Allow the dowel rods to dry for at least 30 minutes before continuing.
- 7). Use the staple gun to staple fleece down to the outer left of the open end of the enclosure.
- 8). Stretch the fleece to the right side of the enclosure, and staple it on the outer right side of the box.
- 9). Stretch to the outer top side of the box and staple. Repeat this for the bottom side as well.
- 10
Apply fiberglass resin liberally with a paint brush. Be sure to coat each part of the fleece. - 11
Allow the resin to dry to the touch, and then add another layer. - 12
Repeat Step 11 until you have three to four layers on the enclosure. - 13
Sand the resin with a coarse sandpaper. - 14
Fill any holes with auto body filler. - 15
Sand the resin again, this time with a fine-grit sandpaper (300-400 grit). - 16
Use a reciprocating saw to cut out the hole for your speaker. Use impressions that the dowel rods leave in the fiberglass as your guide so that you can cut just to the edge of each dowel rod. - 17
Use the hammer to tap on the dowel rods until you you can free them from the glue. - 18
Pull the rods out of the enclosure. These were just to give the enclosure shape, and they are no longer needed. - 19
Place your speaker over the opening and drill the mounting screws in place.
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