So today I was outside working on an install and since I had some down time, decided to make a quick Fiberglass Pod for a 6.5 MB driver. This tutorial is just a quick one so people can get a quick idea of how its done.
Materials :
1/2" MDF
Jig Saw
Router with half round bit
RotoZip with circle cutting jig
Resin + Catalyst
Nail Gun
Saftey Glasses and respirator
Wood Glue
3m General Adhesive Glue
First cut out a the basic mounting plate and the recessed woofer mounting plate. I didnt take enough pictures of the process of building the Recessed mounting plate but basically if you have a 6.5" Woofer your going to cut 2 circles that are like 7-8" in diameter. The 1st circle you will cut another circle in the middle of it at about 6 5/8"s to create the outside ring of the mounting plate. On the 2nd Circle, cut out the middle at the mounting cutout diameter of the woofer so it will fit correctly down on the plate Then take the 1st ring, put some woodglue on it and mount it on the 2nd plate, It should look like 2nd picture shown below.
Next cut some strips of wood and mount the woofer ring in the position you wish it to be pointing on the mounting plate.
Next get some stretchy fabric that will remain tight. I used an old T-Shirt but you can use grill cloth, or a polyester fabric. Spray the mounting ring and the back edges of the mounting plate with 3m spray glue. Then Wrap the skeleton with the fabric and make sure there are no creases. (Make sure its very tight) Then Mix your catalyst and the resin together and soak the fabric as shown below.
If you put the right amount of catalyst in the resin it should be fully dry within an hour. After its dry cut off excess material on the back and sand down any high spots on the pod. You can lay fiberglass chop mat on this to strengthin it or if its strong enough you can bondo and paint it, carpet it or vynl it. Whatever you choose CLAP. I didnt have time to actually cover the product but heres a picture of it sanded.
Well hope that helps with the basic idea. I'll do a more indepth tutorial once i start on my door panels for my truck. i was just bored and decided to throw one together real fast. Enjoy and goodluck. Any questions feel free to ask =)
-PL
Replies (9)
swez on 11/2/2005 09:04:10
Nice prototype Pod. Do you have any idea what the internal airspace for this project would be for that 6.5" speaker mount?
Swez
P0werLifter on 11/2/2005 13:44:36
To be honest I'm not exactly sure. Depending on the exact driver you had and how much airspace you wanted you could midify the skeleton and seal the rear section of the pod or put a foam baffle in the door to make an enclosure. For the pod itself (if the rear plate was sealed) id venture to guess about .058cuft. just a guestimate. =)
-PL
asplundher on 11/2/2005 18:08:00
I noticed that to be a problem on a few designs that I wanted to do. One solution would be to cut a small hole in the back or bottom and use the vehicles carpet as a "resistive leak". Thats if it is mounted on the floor/kickpanel. Another option is to use the same hole affixed (in rear) with a firm (steel, plastic, etc) mesh with fiberglass insulation sandwiched in between to create a small version of a variovent. The insulation could be thickened or thinned to attain the desired effect. The rest of the pod would be filled with polyfil only leaving a small open path to the vent.
JMB on 11/3/2005 00:11:23
I cant wait for ur next tutorial, the pictures really help me get my head around what the stages are. Thanks PL
Regards JMB
P0werLifter on 11/3/2005 16:49:05
No problem JMB, glad it helped someone out in at least understanding the different stages of the process. When I begin the next install i should have a digi cam (i hope). All the pictures ive been taking have been off my cell phone and its a pain in the arse to send em to myself in the mail haha.
admin on 11/4/2005 08:04:44
BANNER1
P0werLifter on 11/13/2005 16:19:39
^^^ Bump^^^
Ash on 11/13/2005 16:51:34
Question: what is the purpose of the opening in the back of the pod?
P0werLifter on 11/13/2005 17:08:14
The depth of the magnet on the driver i was using as a model was to deep so I cut out the back so it would mount. Also if u wanted to make the enclosure larger by cutting a 6.5" hole in the sheet metal on the door and use a foam baffle from partsexpress or crutfield to seal of off and make the airspace larger you could.
Materials :
1/2" MDF
Jig Saw
Router with half round bit
RotoZip with circle cutting jig
Resin + Catalyst
Nail Gun
Saftey Glasses and respirator
Wood Glue
3m General Adhesive Glue
First cut out a the basic mounting plate and the recessed woofer mounting plate. I didnt take enough pictures of the process of building the Recessed mounting plate but basically if you have a 6.5" Woofer your going to cut 2 circles that are like 7-8" in diameter. The 1st circle you will cut another circle in the middle of it at about 6 5/8"s to create the outside ring of the mounting plate. On the 2nd Circle, cut out the middle at the mounting cutout diameter of the woofer so it will fit correctly down on the plate Then take the 1st ring, put some woodglue on it and mount it on the 2nd plate, It should look like 2nd picture shown below.
Next cut some strips of wood and mount the woofer ring in the position you wish it to be pointing on the mounting plate.
Next get some stretchy fabric that will remain tight. I used an old T-Shirt but you can use grill cloth, or a polyester fabric. Spray the mounting ring and the back edges of the mounting plate with 3m spray glue. Then Wrap the skeleton with the fabric and make sure there are no creases. (Make sure its very tight) Then Mix your catalyst and the resin together and soak the fabric as shown below.
If you put the right amount of catalyst in the resin it should be fully dry within an hour. After its dry cut off excess material on the back and sand down any high spots on the pod. You can lay fiberglass chop mat on this to strengthin it or if its strong enough you can bondo and paint it, carpet it or vynl it. Whatever you choose CLAP. I didnt have time to actually cover the product but heres a picture of it sanded.
Well hope that helps with the basic idea. I'll do a more indepth tutorial once i start on my door panels for my truck. i was just bored and decided to throw one together real fast. Enjoy and goodluck. Any questions feel free to ask =)
-PL
Replies (9)
swez on 11/2/2005 09:04:10
Nice prototype Pod. Do you have any idea what the internal airspace for this project would be for that 6.5" speaker mount?
Swez
P0werLifter on 11/2/2005 13:44:36
To be honest I'm not exactly sure. Depending on the exact driver you had and how much airspace you wanted you could midify the skeleton and seal the rear section of the pod or put a foam baffle in the door to make an enclosure. For the pod itself (if the rear plate was sealed) id venture to guess about .058cuft. just a guestimate. =)
-PL
asplundher on 11/2/2005 18:08:00
I noticed that to be a problem on a few designs that I wanted to do. One solution would be to cut a small hole in the back or bottom and use the vehicles carpet as a "resistive leak". Thats if it is mounted on the floor/kickpanel. Another option is to use the same hole affixed (in rear) with a firm (steel, plastic, etc) mesh with fiberglass insulation sandwiched in between to create a small version of a variovent. The insulation could be thickened or thinned to attain the desired effect. The rest of the pod would be filled with polyfil only leaving a small open path to the vent.
JMB on 11/3/2005 00:11:23
I cant wait for ur next tutorial, the pictures really help me get my head around what the stages are. Thanks PL
Regards JMB
P0werLifter on 11/3/2005 16:49:05
No problem JMB, glad it helped someone out in at least understanding the different stages of the process. When I begin the next install i should have a digi cam (i hope). All the pictures ive been taking have been off my cell phone and its a pain in the arse to send em to myself in the mail haha.
admin on 11/4/2005 08:04:44
Nice Work!
BANNER1
P0werLifter on 11/13/2005 16:19:39
^^^ Bump^^^
Ash on 11/13/2005 16:51:34
Question: what is the purpose of the opening in the back of the pod?
P0werLifter on 11/13/2005 17:08:14
The depth of the magnet on the driver i was using as a model was to deep so I cut out the back so it would mount. Also if u wanted to make the enclosure larger by cutting a 6.5" hole in the sheet metal on the door and use a foam baffle from partsexpress or crutfield to seal of off and make the airspace larger you could.
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