Page 1 of 5 123 ... LastLast
Results 1 to 10 of 48
Like Tree4Likes
Discuss How To Fiberglass a Custom Sub Box at the Focus ST Interior within the Ford ST Nation; I had originally ordered an ...
  1. #1
    ST Nation Sergeant
    Join Date
    Feb 2013
    Posts
    83
    Chats
    0

    How To Fiberglass a Custom Sub Box

    I had originally ordered an ST1 because I was going to replace the stock radio anyways with better components but I found out that the only face plate available from Metra looked horrible and made the car look cheap. I decided to purchase an ST2 but upgrade all the speakers and subwoofer while using the stock radio. I'm actually happy I got the ST2 b/c I really like Ford's My Touch. The speech recognition is just unbelievable when I tell it an address to route to.

    Anyways, as for the stereo, it does sound decent but the major weakness is the sub. Its not clean sounding and ends up distorting the mids and tweeters. There's not a lot of room in our trunk so I decided to use a shallow mount sub to mount in the corner to replace the stock sub. I'm not a fan of putting big sub boxes in the trunk b/c it's not aesthetically pleasing and takes up too much usable space. I fiberglassed a sub box in my last car so decided to do one for my ST.

    First, in order to remove the stock sub, you would need to remove the spare tire and then unclip the wire that attaches to the sub. It's attached to the green connector in this picture and you just press the tab to unlock it and pull it out.

    IMG_0151 (Large).JPG

    Remove the foam that sits next to the spare tire and you'll see the 3 bolts that hold the sub in place:

    IMG_0152 (Large).JPG


    This is what the sub looks like removed from it's enclosure:

    2013-02-23 13.24.16 (Large).jpg

    I plan to replace it with an Alpine SWR-T12, it only requires a 0.6 cubic foot sub box and is 3.5 inches deep:

    IMG_20130223_132247 (Large).jpgIMG_20130223_132311 (Large).jpg


    Things you will need:

    Fiberglass resin
    Fiberglass mat or cloth (I find the cloth is easier to work with)
    disposable plastic cups
    disposable gloves
    Ventilator
    painters tape
    petroleum jelly
    acetone
    cheap brushes


    First thing you'll need to do is tape the area you want to fiberglass. It's very important that you double tape everything because the resin will stick to anything and once it's on your carpet/plastic trim or car then it'll be there permanently. I then outlined the area where I want the sub box to be with a marker.

    2013-02-23 16.47.51 (Large).jpg

    Apply a generous amount of petroleum jelly to the area, it will serve as a releasing agent to help you remove the fiberglass frame later.

    IMG_0154 (Large).JPG

    Now cut up the fiberglass mats into smaller pieces, about 4x4 inches. Make sure you wear gloves and use a ventilator mask when working with fiberglass.

    IMG_0157 (Large).JPG

    Mix up a SMALL amount of the resin in a plastic cup. In a red solo cup, I usually pour to the first line at the bottom and add about 20-25 drops of the hardening agent and mix it really well with a plastic spoon. Use the brush to dab a small amount onto the painter's tape and then lay a fiberglass mat on it then dab some more until you soak the mat thoroughly. It'll turn from white to clear once it's soaked thru. Move from one area to the next, using only a small amount of resin at a time because you only have about 15 minutes to work with it before it hardens. Don't mix too much at a time or else you'll just waste it. In between mixing the resin, be sure you place the brush in a glass of acetone to prevent the fiberglass resin from hardening it. Here's what it looks like after 2 layers:

    IMG_0159 (Large).JPG

    Add about 4 layers of resin & mat and l let it dry overnight. I used a screwdriver to carefully pry at the corners and loosen all the outside edges.

    IMG_0163 (Large).JPGIMG_0164 (Large).JPG

    Once all the edges are pried apart, yank on the bottom (holding onto foam insert) and you can hear it slowly releasing. This is the most difficult part because it's stuck on pretty good but if you pull on the corners, you'll eventually get it freed.

    IMG_0165 (Large).JPGIMG_0166 (Large).JPG

    Clean the back side of the fiberglass frame with some dish washing soap to clean off the petroleum jelly. After cleaning it, I put it back into the car to mark where I need to trim it.

    IMG_0167 (Large).JPG

    Using a dremel, I cut it to the size I want and file away the rough edges. Here's the final back side of my sub box.

    IMG_0168 (Large).JPG
    Last edited by SGPMan; 02-25-2013 at 10:03 PM.
    Chad likes this.

  2. #2
    ST Nation Sergeant
    Join Date
    Feb 2013
    Posts
    83
    Chats
    0
    The next step is to attach the sub ring that I had cut out of an MDF board. I used hot glue to attach the dow rods and then glued it to the back of the sub box.

    IMG_0182 (Large).JPGIMG_0183 (Large).JPG

    Now take an old T-shirt and stretch across the front of the sub box and use the hot glue to secure it down.

    IMG_0184 (Large).JPGIMG_0185 (Large).JPG

    I then used a marker to outline where the border of the sub box is

    IMG_0186 (Large).JPGIMG_0188 (Large).JPG

    Soak the T-shirt thoroughly with resin and then layer it with fiberglass mat

    IMG_0190 (Large).JPGIMG_0191 (Large).JPGIMG_0193 (Large).JPG


    I'll let it dry overnight and then cut out the center and continue layering the resin & mat from the inside.
    Last edited by SGPMan; 03-10-2013 at 07:45 PM.
    Chad likes this.

  3. #3
    ST Nation Sergeant
    Join Date
    Feb 2013
    Posts
    83
    Chats
    0
    Here's the box with the center cut out and after some rough sanding:


    IMG_0196 (Large).JPGIMG_0197 (Large).JPG


    Test fitting the sub into the box:

    IMG_0198 (Large).JPGIMG_0199 (Large).JPG

    Making sure the box fit into it's corner:

    IMG_0200 (Large).JPGIMG_0201 (Large).JPGIMG_0202 (Large).JPG

    It's a tight fit, but I'll make it fit. I'll just need to file away some of the foam inserts.

    I then applied some Bondo and then sand it down with 40 grit sandpaper to even it out as much as I can:

    IMG_0209 (Large).JPG

    I bought some black car carpet from Autozone and used Loctite spray on adhesive to glue the carpet to the box.

    IMG_0222 (Large).JPG

    I'm not very good at carpeting, there's some seams that I'd rather not be present but this is the best I could do:

    IMG_0215 (Large).JPGIMG_0216 (Large).JPG

    And with the top cover on, it's hidden from prying eyes:

    IMG_0221 (Large).JPG
    Last edited by SGPMan; 03-25-2013 at 05:04 PM.
    Chad and billym1130 like this.

  4. #4
    ST Nation First Sergeant
    Join Date
    Oct 2012
    Location
    Michigan
    Posts
    317
    Chats
    2
    Occupation
    Engineer
    My Ride
    PB ST1
    Name
    Nick
    Awesome! I've always wanted to try fiberglassing.

  5. #5
    ST Nation Private
    Join Date
    Dec 2012
    Posts
    15
    Chats
    0
    Love it. I was thinking the same thing, filling in that whole side and coming to about the same spot the stock sub goes, should gain a decent amount of airspace by going that route. Looking forward to the updates.

  6. #6
    ST Nation Master Sergeant Bizzaroh's Avatar
    Join Date
    Apr 2012
    Location
    hills of WV
    Posts
    246
    Chats
    0
    Occupation
    Network Engineer
    My Ride
    White ST3
    Are you planning on just using the stock amplifier or are you adding an aftermarket ontop of it?

  7. #7
    ST Nation First Sergeant
    Join Date
    Feb 2013
    Location
    Allentown, PA
    Posts
    359
    Chats
    0
    Occupation
    Systems Engineer
    My Ride
    2013 Ford Focus ST
    Name
    Wes
    This is cool. I installed custom stereos while in college. I haven't done something like this in years. If I could make what I make now and install stereos that is what I would still be doing. Looking forward to seeing how tis turns out.

    Wes

  8. #8
    ST Nation Sergeant
    Join Date
    Feb 2013
    Posts
    83
    Chats
    0
    Thanks for all the encouragements! I just got home from work so didn't get a chance to work on the box tonight. I'm off tomorrow so should have some updates for you guys soon.

  9. #9
    ST Nation Sergeant
    Join Date
    Feb 2013
    Posts
    83
    Chats
    0
    Quote Originally Posted by Bizzaroh View Post
    Are you planning on just using the stock amplifier or are you adding an aftermarket ontop of it?

    No, the stock amp won't be able to power a decent aftermarket sub. My setup will consist of:

    Dynaudio Esotec components up front
    DLS coaxials in the rear
    Alpine sub
    JL HD 600/4
    JL HD 900/5
    Bit One processor

    I'm still debating how to connect the stock radio to the Bit One. I've read some posts where I'm told to wire it before the stock amp while others say the signal is too low so I would wire it after the stock amp. I'd prefer to wire it before since the amp may distort the signal.

    IMG_0170 (Large).JPG

  10. #10
    ST Nation Master Sergeant Bizzaroh's Avatar
    Join Date
    Apr 2012
    Location
    hills of WV
    Posts
    246
    Chats
    0
    Occupation
    Network Engineer
    My Ride
    White ST3
    Quote Originally Posted by SGPMan View Post
    Dynaudio Esotec components up front
    DLS coaxials in the rear
    Alpine sub
    JL HD 600/4
    JL HD 900/5
    Bit One processor
    Wow that looks pricey! What is your total cost so far?

    Where are you going to mount the amplifiers? To the back of the back seats?

Page 1 of 5 123 ... LastLast

Similar Threads

  1. How custom ordering works?
    By SoonToBeSTOwner in forum Focus ST General Discussion
    Replies: 8
    Last Post: 02-14-2013, 01:18 PM
  2. I've given up on my custom ST3 order....
    By Bagdasar in forum My ST
    Replies: 5
    Last Post: 11-18-2012, 08:16 PM
  3. Custom Exhaust
    By jakebrewer in forum Focus ST Performance
    Replies: 60
    Last Post: 10-29-2012, 08:36 AM
  4. Anyone going Carbon Fiber / Fiberglass RS-type hood?
    By Americarsftw in forum Focus ST Exterior
    Replies: 21
    Last Post: 10-05-2012, 06:37 PM
  5. Ford Custom Graphics
    By 1chrisb in forum Focus ST Exterior
    Replies: 10
    Last Post: 06-26-2012, 06:15 AM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •