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Old 10-16-2013, 10:57 AM   #1
DVolpe
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Custom Cargo-Cover Fiberglass Enclosure

This project is making a mold of the cargo cover lid and creating a 12" subwoofer enclosure. Ive had my box in my trunk and it takes up almost half the trunk. And my creative little mind came up with this idea. I have been wanting to do this project for awhile and finally got a free weekend to start working on it.

I have never worked with fiberglass before and all my knowledge is from youtube videos haha

to be warned I went pretty heavy on the photos to try to go step by step. And the the bright green kitchen is not mine haha. This is at my girlfriends house, I live in downtown baltimore and there isnt much room for projects like this.

I started by removing all the pieces and



Then wrapped the OEM cover in aluminum foil and sprayed it with cooking spray so the fiberglass would not stick to the OEEM cover. I also added a bowl to give the box shape for the speaker cone


Added one layer of fiberglass to the outside ring to have a solid surface to attach the fleece to


first fiberglass FAIL, added too much hardener and the resin hardened before i could use it all


Stretching the fleece to shape the bottom


Came out great after I applied resign directly onto the fleece and it is hard as a rock!


Flipped right-side up and mounted the speaker ring. I was able to get a MDF flush-mount speaker ing for $13 on ebay with free shipping! thats almost the cost of the wood, so free labor


Stretched fleece on the top


Added some fiberglass to seal up the holes and add strength to the edges


Grind time


A few more cuts, sanding and some magic she fits like a glove


Right side is flush



but the left needs some work

IMG_7346 by davevolpe, on Flickr

I still have a lot of sanding and bondo work to do to make her smooth. In the end the bottom will be spray painted black since no one will see the bottom and the top will be wrapped in carbon fiber vinyl to match my dashboard. The amp will also be mounted to the back of the seat so there will be no junk in the trunk



Last edited by DVolpe; 10-16-2013 at 01:38 PM.
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Old 10-16-2013, 12:30 PM   #2
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Looks awesome!!!!!
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Old 10-16-2013, 01:05 PM   #3
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The Idea is there =D

But wouldn't it rattle to ?
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Old 10-16-2013, 01:19 PM   #4
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Interesting.
Good work.
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Old 10-16-2013, 01:25 PM   #5
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Moved to "Mk3 Interior Mods & Upgrades"


Are you going to poly fil the box when your done? You may have some time to track down the rattles.
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Old 10-16-2013, 01:28 PM   #6
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But wouldn't it rattle to ?
Thought about that and I am looking around to see if I can find some thin weatherstripping to keep it nice and snug. If not I think just some think stripes of felt where it rests on the lip will make enough of a shock absorber to not have it rattle.

But who knows, it is all trial and error. that is why o made a mold from the original cargo lid so I still have that and can remove this whenever.
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Old 10-16-2013, 01:31 PM   #7
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Are you going to poly fil the box when your done? You may have some time to track down the rattles.
Yep poly filling since it is such a small space. And looking for some thin padding to line in-between the enclosure and body panel.
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Old 10-16-2013, 06:49 PM   #8
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If I were you I'd definitely add tons more fiberglass. I've never seen it done with just the fleece and resin. I thought the fleece was just used to have a surface to add the fiberglass to. But dang another reason why I want a hatchback....to get anything like that in a sedan you'd have to cut through metal and insulation and its just all bad.
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Old 10-16-2013, 06:57 PM   #9
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Awesome work! Subbing
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Old 10-16-2013, 07:18 PM   #10
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If I were you I'd definitely add tons more fiberglass. I've never seen it done with just the fleece and resin. I thought the fleece was just used to have a surface to add the fiberglass to. But dang another reason why I want a hatchback....to get anything like that in a sedan you'd have to cut through metal and insulation and its just all bad.
No the fleece absorbs the resin the same as fiberglass does. It's the same as fiberglass, the fleece just makes a better shape. It is very sturdy


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