What kind of box are you putting that monstrosity in, anyway?

...oh, and one last note about the 'relax' thing, I have a whole week of vacation set aside to relax...oh, wait...that's the audio install week.

 

3.2 cu ft box, tuned to 28 hz with a 3.5" wide port opening

haven't decided if i should just stick with bare MDF or have it carpeted.

 

sand it and stain it

 

Alright, time to fill that ugly gap in between the console and the air vents. I started by taping up the sides of the dash and the underside of the vents, and place a trash bag on top of the shifter assembly.



Then I glopped the tiger hair into the gap...



...then I cut the excess around the vents as best I could using a straight razor.





Of course I will have to clean the lines up a bit more, but I will save that for Monday when everything is cured!

 

have you done this stuff befoe with interior parts?

 

i wish i could figure out how to do this, i wanna make a box for 2 12's, i was going to try but gave up, you're doing an awesome job though

 

Nope, never. My first fiberglassing project was with the trunk...this is my second.

 

Can I get this link too or can you burn me a copy of the DVD I'll send you some money for it. Project looks great I want to do some fiberglassing this summer.

 

Ok, EXCITING DAY!!!!! I started off by sanding the tiger hair so that I could close the gap between the console and the air vents...all in all, it looks pretty good. I am still going to have to perform some very delicate sanding to get it perfect, but this is as far as I needed to get it before the next step.



...and now, for a close-up! It's quite flush, but there is still a leeeeettle gap I will need to fill. I'll show you how in the next step.

 

Now, remember how last time I used way too much MEKP when making he 50-50 mix of body filler and resin? Well, this time I wised up and scaled the MEKP back, and the body filler up. The result? A much less-viscous liquid to deal with. The pour went QUITE nicely and filled in +95% of the gaps! Tommorow, WE SAND.

 

What is mekp? Is it the hardener.

Do you just mix body filler and fiberglass resin (50-50). I use regular body filler or the spayable kind but, if this is easier to work with then I might try it.

-Sean

 

Methyl Ethyl Ketone Peroxide...it's the hardener. But keep in mind, the only reason I used this was to fill gaps and is easier to sand than fiberglass.

 

silly question...but is it literally tiger hair? or is it a nickname they give the fibers? (total n00b at this stuff)

 

haha...nah, it's just a REALLY thick body-filler mix with fiberglass chop strands in the mix. It's tough to work with, but manageable.

 

ah, gotcha

 

Subscribing.

Excellent work...!!

Waiting for more pics

 

Dan....loving this tutorial...I was hoping to meet you at the meet-what happened?

 

Thanks, Manny!

Sorry I couldn't make it - my Aunt (Mother's only remaining sister) & Uncle were having the family over for a bbq on Sunday. My mom came VERY close to passing two years ago and ever since that night, she and her sister have grown very close. It means alot to my Mom that I am present for things of this nature, so to skip something she hosts is simply out of the question. Call me a die-hard family man.

I would have loved to see ya take first place and, more than anything, the obligatory jaw-dropping from those out-of-the-know when you recieved your Maxina trophy!

 

Completely understandable....I was hoping to see some more audio guys there...we def have to get together sometime....maybe you can make it to the ECA meet I have planned for July 24th. Same place, Same time. Smal gathering of 10+ cars w/ some cool toys and knowledeable people.

 

Ok, SO...nothing fun today. As with any project, I ran into a set back on this one. Whe I poured the resin on the peice, I didn't add enough MEKP, and, after 24 hours, the mix never cured! You can kind of see where the resin separated from the body filler (poor mixing, too) in the peice. It was plenty hard, but the surface was all sticky. Plus, there were some holes left too. Ugh



As you can see here, it cured for the most part...heh-heh. These brickers are QUITE fused.



So, after a trip to Pep Boys for some more body filler and HD for some more resin, it's time for a second pour. I used more MEKP than I needed, and made sure it was thoroughly mixed. This second pour turned out even better than the first! The peice is almost completley level now.

 

That's all for about a week, folks. Tommorow I spend with the missus and maintaining my fishtanks (my other hobby ), Thursday I am packing for a wedding, Fri - Sun. is the wedding, Monday is a day of rest, and Tuesday is Ozzfest. I might be able to get to this on Wednesday, but we'll see just how exhausted I am at that point in time!

 

Seems like you are haveing too much fun

Great job

 

looking good as usual man.

 

in for more pics

 

still looks good dan - nice progress and props for keeping us posted


...that piece must be a heavy sumbish?

 

Posting to bump and in for more pics as well...

 

Thanks, Nilesh! YEAH, that thing is indeed starting to get fairly weighty . Fortunatley, alot of the material in the front is going to be cut out for the various units. That should take some of the weight off. BUUUTTT...I am still going to have to add more body filler to smooth out a transition line that is still peeking through...I just have to remind myself to NEVER handle the unit by the shifter console!

 

Eagerly awaiting the final result. This is definitely a motivator for some of the projects I have to come. Keep up the good work and keep us posted.

 

Any more status? I do like the progress so far.

 

Dan's a slacker.

I'm no better

 

Haha, today is the FIRST day I have had to work on this in close to a week. I could have worked on it yesterday, but I'm blaming the hottest day of the year and an outdoor metal concert on that. I'm sunburnt and sore as @#$%, but that will not dissuade my efforts in the least, although I'm only operating at around 75% right now.

I should have some picks later on today after the bodyfiller cures, at present I am working on filling the gap btw the air vent corners and the console. I also got my leather kit yesterday, and it looks like the match btw the paint and the bone leather is PERFECT...things are really starting to shape up!!!

 

on the fiberglassing and the fishtanks!! You are braver than me to actually glass the majority of the project in the dash, I know masking tape is our friend and all but I would be on pins and needles. Boy that resin is stupid high right about now, I remember last year it was like $22 a gal, now its over $31. I had a buddy of mine that works at a boat factory acquire me some. Keep up the good work man, I'll be posting pictures of my fiberglass box soon as well.

 

Alright, I took a little nap around 3 today and fortunatley it gave me the energy I was looking for! I spent the day fit-testing and sanding the peice. So far the 60-grit phase is done, hopefully tommorow or Friday I can move through the 200, 500, and 1000 phases. Here is a pic of how the current console lines up with the air vents...it's ALOT harder to do than I thought!





We might have some work to do on this end...



This last pic is another 'teaser' of sorts...just some more of the two-toning!

 

Well you were right about the two-tone match, thats for sure. Can't WAIT to see how it all comes together.

Oh yea, fglassing looks good too

 

looks real good man.

 

Very nice work man, I can't wait till its all done!!!

 

this looks like it's comming together nicely. Nice job

 

wow nice job... your cars going to looks sick bro

 

The labor on your seats will make your fiberglassing project look like cake ... trust me

 

and I think the deadening will make that look like cake! Best of all, the install will occur under the scorching August sun. btw, ygpm.