- 1). Build a frame for the speaker panel. This can be made of plywood or any other framing material. If building a speaker panel into a door panel of a car, remove the door panel and cut away the surface where you want to mount the speaker. The frame for the fiberglass panel should be made to fit flush to the surface you will mount the panel to, and needs only to strong enough to hold the fleece in place before covering it with fiberglass. You do not need to include a full back portion to your panel, just the skeleton needed to hold the fleece in place.
- 2). Make a wooden ring bracket to mount the speaker to later. Trace the speaker's frame onto a 1/2-inch thick sheet of plywood and cut it out with a jig saw. It only needs to contour the edge of the mounting bracket around the perimeter of the speaker frame and should be only about 3/4 of an inch thick around, with enough surface area to screw the speaker to it later. It will be held in place with fiberglass, providing a solid-wood surface to screw the speaker into. The speaker mounting ring will be mounted to the fleece with thumb tacks before being permanently incorporated into the panel with fiberglass.
- 3). Stretch a single layer of fleece fabric over the panel. The fleece will provide a flexible surface that you can mold and shape just the way you would like it. Support it from the back with scrap wood blocks if desired, and place the wooden mounting ring from Step 2 where you would like it permanently mounted. Tack the fleece in place using thumb tacks.
- 4). Mix the epoxy resin and hardener together according to the manufacturer's instructions. Paint on a layer of resin evenly over the fleece then allow it time to cure. Curing takes place over the course of several hours and will slightly harden the fleece, allowing you to coat it with fiberglass later.
- 5). Coat several sheets of fiberglass cloth with the epoxy resin and apply them evenly over the surface of the fleece. Once cured, these fiberglass sheets will form a rock-hard surface for the speaker panel. Add a second or third layer of fiberglass cloth depending on the strength you desire.
- 6). Sand the cured and dried fiberglass smooth after allowing the epoxy time to cure to a hard finish. Shape and sand down any rough areas using rough grit (80-120) sandpaper wrapped around a sanding block.
- 7). Paint the smooth fiberglass surface using a paint of your choice, or cover with a fabric or vinyl that suits your design needs. Mount the speaker by screwing it into the plywood ring bracket that is now firmly embedded into the fiberglass panel. Connect the electrics for the speaker and enjoy.
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