Originally Posted by Purplefade

Hey Clockwork,

I got side-swipped by my (wifes) bathroom project and haven't yet finished it, but what I did was make a cardboard "mold" (using that thin but stiff type of cardboard that you find on the back of a yellow note pad, scissors and tape) of the entire back cavity of the truck and then wrapped the inside of the mold with plastic wrap, laid in fiberglass matte and used resin and hardener to set it up - so far so good.

I am going to finish it by tracing the face of it on 1/4" ply wood (doubling up just the area where the sub will screw in) and cutting that just inside the line so that it will fit inside the lip of the fiberglass enclosure. Tap some screw hole through the enclosure into the plywood, add a bead of construction adhesive for good measure and seal the enclosure to the face board and wrap the entire enclosure in a second layer of fiberglass for structural integrity.


I figured that by using fiberglass and keeping it thin and rigid that I could use more of the air space and take up more of the nooks and crannies vs using 1/2" or 3/4" particle board like most do.


I ordered everything online from home depot and had it dropped off on my front porch for an additional $8.99 delivery fee - it was awesome!


Edit: - Missed the part about cost - best part, it was SUPER cheap!
I spent like $15 on the resin, $12 on the fiberglass cloth and matte (I used cloth to mold the inside initially, it's softer, and will go back over the whole box with the matte once the face is attached), and the plywood was like $9 if I recall right.


It required:
4'x4' piece of thin, rigid cardboard
scissors
painters tape (I used pt because it doesn't stick down until you press it good which gave me an opportunity to adjust the pieces)
1 - $14 quart resin w\hardener included
1 - $6 package of fiberglass cloth
1 - $6 package of fiberglass matte
2 - cheap paint brushes
rubber gloves
1 - $9 4'x4' piece of 1/4" plywood
1 - $2 10oz tube of liquid nail
caulk gun
jig saw


And my wife having an absolute fit about the smell of the fiberglass on me when I came in from the garage...