Installer Institute: Custom Sub Box - PAGE 2

Step 7 Again, five layers of 1 ½ oz fiberglass mat was cut and applied one layer at a time over the entire panel. Special note: While the fiberglass is drying you have about a 2 minute window that the glass is strong enough to trim with a razor blade this will help prevent you from having to grind a lot of fiberglass. With the glass dry the base of the project was separated from the top and all the foam was removed from the inside of the project.

Step 8 Because the panels were built together they will almost snap back into place. To help hold the two parts together extra thick super glue was used around the entire seam. We don’t want to permanently attach them together yet incase we run into a problem when we do our final test fit. Next two rings were cut one to surround the speaker and one to be used as an accent piece for the project.

Step 9 The speaker use set into place and taped up to protect it form filler. The speakers wood ring was also taped with 4 layers to compensate for the thickness of the suede and paint that would be applied later. Dura-glass was mixed up and used to fill in all the areas above and below the accent ring. Once dry it was popped out and trimmed.

Step 10 With the accent ring done it was time to form the ring to the box. To do this it had to be taped with a layer of 2” masking tape, then a layer of double sided tape (compensate for material thickness) and a last layer of masking tape to hold the double sided tape in place. Then body filler was mixed up and applied to the entire panel including accent ring. Once dry the box was sanded smooth.

Step 11 The accent ring was removed from the panel and taken to our spray booth where high build primer and color match base and clear were applied to the accent ring.

Step 12 It was decided to cover the panel with black suede, contact adhesive was used and sprayed on both the box and the back of the cover material. Special note: It is always a good idea to use a new pair of latex gloves to protect the new material. The speaker ring was next to get covered.

If you would like to build your skills as a mobile electronics installer and learn from the best fabricators in the industry log onto our web-site www.installerinstitute.com and see what the Installer Institute can do for you.

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