Mod, not sure if it goes here.
Disclaimer: I'm in no way a professional. This isn't a "how-to". I'm simply sharing "how I did it". This is my second fiberglass box ever and the first one I did was done over 8 years ago and ended up in the trash. If you follow me down this road, you've been warned and I'm not responsible.
So, now that that's out of the way... I've finally made it through my engine swap, transmission rebuild, and rebuilt my front end. I thought it's about time to stop with the mechanical and add some perks to the ride enjoyment aspect of my bronco.
Last weekend I added the alpine ktp-445U amp and some new infinity kappa series speakers all around. This gave me awesome mids and highs but really left something missing in the low department. After searching on here and gofastbroncos, I decided I wanted to do something a little different when it came to a sub box. I like driving with the top down and didn't want anyone walking by to see a sub and leave me bass-less. I also wanted to be able to hear the music in the event I had my top off.
I decided to chop up my center console and do a custom fiber glass box, with a downward firing sub. Because of space and the fact this was my second fiberglass build ever, I decided midway through the project to do an 8" shallow mount MB Quart sub.
Plain Jane factory center console out of my 1990 brick nose.
Since I'm going downward firing sub, I needed to chop the bottom up so sound had a place to go and wouldn't be trapped in the console. I decided to take some of the lip of the sides and front, I might add another cut to the back, haven't fully thought out impacts yet...
Next I had to figure out how I wanted to support the box and keep my cup holders. I ended up cutting a piece of 1/4" MDF and shaping it to the upper lip of the console right under the cup holders:
I also wanted to keep some of the console usable for when I'm not driving around. I decided to cut another piece of MDF, this time 3/4" thick and make a back for the box. This is the point I decided to do an 8" instead of a 10". I just didn't think I could pull the correct volume for a 10" and keep the console semi-usable. I'm hoping I don't regret the decision. My thought is that the sub is about 3 feet from my ear, an 8" should be enough to enjoy bass over the road noise and my exhaust.
Next I yanked out my staple gun and secured the fleece for the fiberglass portion to the bottom of the 1/4" MDF.
And carpeted / added terminal connectors to box. I forgot to buy black wood screws, so silver for now. I'll revisit this later....:
Now for the fun. I cut my speaker mount out of the 3/4" MDF using a dremel. It got the job done, but if I ever do this again I'm buying a router and hole jig:
I was torn about whether or not to recess the sub in the box. Ultimately I ended up doing it, but again, this was a pain in the *** using a dremel.
Next I decided to use spay adhesive to attach the fleece to the sides of the console:
And then I did a layer of fiberglass resin to mold the box into the shape of the console:
Time to see where the MDF ring will go. Here's a picture of the test fit. I wasn't too concerned with the console mounts and the speakers movement. There's a 1/4 inch of mdf above the speaker level and there's also another 1/2 inch between the top of the MDF and the console mounting holes:
Next I pulled the speaker out, stretched the fleece from the sides of the box to the recessed lip of the MDF ring and laid some more fiber glass. Here's where my lack of experience with fiberglass shows. It's rough on the eyes, but the shape is exactly what I'm looking for:
And that's about all I got to today. I'm letting the fiberglass set tonight and while I'm at work tomorrow. Tomorrow night I'll start the fun process of doing a good 2-3 layers of fiberglass mat and resin and hopefully I'll be able to drop it in this weekend.
I'll update with more pics as the project evolves!
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