Bossman150

Thanks to MaximaDrvr's nice build log I had a good idea on what to do. I have all the fiberglass part of the build done, just waiting on it to cure enough to take it out. 50's and rainy here so it will take a while.

Somehow I was missing 2 bags of fiberglass cloth, so I ended up using some cotton sheets as my final layer. here are a few pics of the process so far:

http://s1381.photobucket.com/user/bo...tml?sort=2&o=0

MaximaDrvr

iTrader: (1)

Looks good so far.

Bossman150

Pulled it out this afternoon, the non-stick Reynolds wrap worked like a charm, not a thing stuck to it. I used some cooking spray on the parts of the duct tape that were going to be under the resin as well. Still in the 50's here so it's not quite cure yet, stuck it in my dad's workshop and cranked the heat up to 75.

MaximaDrvr

iTrader: (1)

That will definitely help. I don't even bother doing glass here till it is 65 and up. I also won't do it when it is over 85, or at least in the shade, just because I don't want to.
Gives me a couple month window to work in.

Bossman150

Well I must have screwed up a bit lol, tried to fill it with water today and it leaked, sigh. I will have to add more layers to the bottom and probably some to the sides to make it a bit more rigid.

MaximaDrvr

iTrader: (1)

Leaked how?
Through the material?
If so, you didn't use enough resin. I used over 1/2 gallon on just 3 layers.
You may have trouble adding to the bottom, as it may not contour to the trunk tub anymore.
Sand the inside with 60 grit, clean it out so there is a good surface, and build on the inside. You can paint a thin layer of resin for the cloth to stick to when you start.

Bossman150

Yeah, through the material. I had a hard time getting the layers to stick, I think because it was too cold and it just was not hardening enough between layers. So I think they separated enough in a couple places to leak.

This time I will just have to use a respirator and work in my dads shop where it is warm enough. Yeah I meant the bottom, but from the inside. I will add 2-3 layers to the bottom part and 1-2 to the sides as well. I used about 2.5 quarts, so actually more than half a gallon but this was my first time and I don't think I did a good enough job laying the cloth out on the first couple of layers. I will overlap my strips more this time. Also the cloth I got from Home Depot was like bible paper thin crap, I ordered some different stuff to try and if I don't like that I will just use more of the old sheets I have.

MaximaDrvr

iTrader: (1)

You can go to a fabric store and buy fleece as your material.

Bossman150

Ok thanks, I will do that if the stuff I ordered isn't any good.

Bossman150

Ok did some more work on this today. This morning I sanded down the last layer I put down with a disc sander, and took off a lot of the areas that had voids because the layers didn't stick together. Then I used a bit of bondo and filled in the voids.

This afternoon after it had dried good I sanded again and put down another layer of fiberglass, I used fleece this time and I used a LOT more resin, things stuck much much better. I don't think I used enough resin last time, but I have now used an entire gallon of it. It's in my dad's workshop and I have the heat cranked to 75, should be good to go on Monday when I get back there.

Bossman150

Did some more work today, got the divider glassed in:

http://s1381.photobucket.com/user/bossman0150/profile/

Also received my Knukonceptz 8ga speaker wire in the mail. No room for terminals so I am just going to route a couple spots on the MDF top and run the wire between the firberglass and top.

MaximaDrvr

iTrader: (1)

Looks good

Bossman150

Almost done! Got everything cutout and the top attached:

bossman0150's Recent Uploads | Photobucket

MaximaDrvr

iTrader: (1)

What are the smaller holes for?

Bossman150

4" ports, just going to use PVC. I need 16in in each side to tune the box to about 36hz. Most of the ports will be external so they will bounce off the trunk lid.

Bossman150

All done! I have to say this was a ton of work, especially since I am not the handiest of people. Thank goodness my dad is and he was able to help and make suggestions at some crucial points. I can't comment on sound yet, my installer is going to hook it up and set the gains on Monday afternoon. I can't get to the speaker wire end of the amp without un-mounting it so I will let him do it. I don't have the port sealed in yet, I wanted it to be able to be moved around a bit and find where it sounds best and paint it black. Looks a bit silly at the moment. It's not flared but I did taper the ends with a router and smoothed the edges.

http://s1381.photobucket.com/user/bo...=recent&page=1

1996blackmax

iTrader: (2)

Congrats! Let's us know how it sounds.

Bossman150

So I had my installer hookup my 10w6 in my new custom spare tire enclosure. I was expecting a difference, but Holy Mary mother of God, I was not expecting this!! I still don't even have the port sealed yet, its just sitting in the hole loose. Anyway my salesman (who wants to sell me a second 10w6 of course lol) brings me my keyfob and tells me he doesn't think its much louder, but it sounds deeper. My installer rolled his eyes at him so I figured it was louder.

I get in and play the first song I know has decent bass, turn the volume up only to 20, turn the gain **** back below half and listen to Another Brick in the Wall by Korn. Takes a bit for that song to get rolling and when the bass starts to hit I nearly crapped myself! It was so frigging loud I thought sure something was wrong, I thought my rear view mirror was going to fly off. I frantically turn the remote gain to 1/4 and look up to see my installer laughing so hard at me he was bright red fighting to get air lol. It took him a good minute or two to gain his composer only to lose it again after he said, "Dude, you should have seen your face!"

So, needless to say all my hard work on the box was worth it!! When I popped the trunk to listen there is a ton of noise from the port since it's not sealed, but I could not hear it inside the car. The amount of air that comes flying out of the port is just crazy! I put it in the right spot, smacks right into the trunk lid. I'm in love. I don't see myself getting a 2nd 10w6 anytime soon, just this one in a proper box is just unreal. I can't believe how much the prefab box was smothering this amazing sub!

1996blackmax

iTrader: (2)

Glad your happy with it

I felt the same way when I put my 10W6v2's into a bigger enclosure than the JL box they came in....first noticeable thing was how much deeper the bass was. Just better overall sound. Ever since then, I followed this rule with my 12W6 & 13W6.

MaximaDrvr

iTrader: (1)

I told you that you probably didn't need two of them. Can you even imagine what doubling the output would sound and feel like?

Bossman150

Completely agree now lol, I have it all setup for two if anything ever changes but I highly doubt it. This is wayyyy more than I was expecting from 1 10.