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IMG_5885
Hatch cargo area before sub install
Date: 04/14/2012
Views: 5462
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IMG_5891
Weak Bose factory sub-woofer
Date: 04/14/2012
Views: 1207
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IMG_5894
Cargo area floor board with foam supports
Date: 04/14/2012
Views: 1254
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IMG_5898
Spare tire with factory sub-woofer removed, this is where the stealth box is going to be installed
Date: 04/14/2012
Views: 1324
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IMG_5901
Initial materials used to build the box. I ended up buying another gallon of resin and two (2) cans of Bondo-Glass
Date: 04/14/2012
Views: 1205
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IMG_5904
Two (2) sheets of 1/2" MDF for the box face
Date: 04/14/2012
Views: 1240
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IMG_5905
Blocks to elevate the foam support around the spare, this gives me room to build up the lip of the enclosure and gain much needed volume
Date: 04/14/2012
Views: 1302
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IMG_5907
Make sure it's level before taping the blocks with gorilla tape
Date: 04/14/2012
Views: 1344
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IMG_5920
Eclipse XA1000 Mono-block amplifier. This will be the 3rd car I've used this amp in and I love it! I was playing around with mounting the amp in the cargo area, but settled with mounting it under the driver's seat.
Date: 04/14/2012
Views: 2149
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IMG_5940
Fiberglass prep work - Foil
Date: 04/14/2012
Views: 2319
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IMG_5946
Building up the lip of the enclosure for additional volume
Date: 04/14/2012
Views: 2581
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IMG_5948
More foil
Date: 04/14/2012
Views: 1191
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IMG_5950
Now the tape
Date: 04/14/2012
Views: 2775
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IMG_5953
More tape
Date: 04/14/2012
Views: 1286
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IMG_5957
Even more tape - I should have taped up the lip as well, but it turned out ok
Date: 04/14/2012
Views: 2865
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IMG_5959
Making sure the trunk is safe from resin
Date: 04/14/2012
Views: 1160
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IMG_5963
Prepping the fiberglass for initial application
Date: 04/14/2012
Views: 1094
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IMG_5964
First application of glass. Slow and steady is the key, you want to make sure you don't have any bubbles etc.
Date: 04/14/2012
Views: 1070
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IMG_5965
I realized after bending over and killing my back for hours that I could just remove the spare tire and work with it at a more comfortable table height
Date: 04/14/2012
Views: 1142
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IMG_5965
More fiberglass
Date: 04/14/2012
Views: 1149
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IMG_5967
A lot of fiberglass for this enclosure, a minimum of 6 overlapping layers by the time it's done
Date: 04/15/2012
Views: 1266
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IMG_5968
This is the trunk with the elevated supports, almost no distinguishable difference from the first pic
Date: 04/15/2012
Views: 1127
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IMG_5971
Strips of woven fiberglass cloth to fortify the lip of the enclosure
Date: 04/15/2012
Views: 1390
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IMG_5975
About half way through the glassing, I can now remove it from the spare tire
Date: 04/15/2012
Views: 1302
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IMG_5979
Unwrapping the back of the enclosure
Date: 04/15/2012
Views: 1160
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IMG_5981
Most all of the foil and tape came off, the rest had to be worked at and a small amount was embedded in the resin
Date: 04/15/2012
Views: 1322
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IMG_5983
Starting to look pretty decent
Date: 04/15/2012
Views: 1290
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IMG_5992
Many layers of glass later I fortified the inner lip of the enclosure with Bondo-Glass
Date: 04/19/2012
Views: 1015
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IMG_5999
Getting ready to cut out the top of the box with a home-made jig for my plunge router
Date: 04/22/2012
Views: 1232
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IMG_6001
I cut it out in three (3) passes so as not to overheat the cutting bit
Date: 04/22/2012
Views: 951
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IMG_6003
A perfect circular cut - I LOVE IT!
Date: 04/22/2012
Views: 982
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IMG_6005
Cutting out the sub ring for the 2nd piece to be laminated to the top of the enclosure
Date: 04/23/2012
Views: 1164
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IMG_6006
The router jig is the only way to go for these cuts
Date: 04/23/2012
Views: 1209
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IMG_6009
Test fit of the sub in the cut-out. The 2nd piece is cut from a piece of MDF I tried to free-hand cut for the top of the enclosure before creating the jig pictured above. It will be cut out in a 12x12 square and laminated to the top piece.
Date: 04/23/2012
Views: 1359
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IMG_6012
3/16's inch deep cut with a 1/2" rabbit bit to recess the sub a little more. Total recess will be 11/16"
Date: 04/23/2012
Views: 1186
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IMG_6015
Cutting out the sub ring for the top piece
Date: 04/23/2012
Views: 1497
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IMG_6017
The top and bottom piece together
Date: 04/23/2012
Views: 1382
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IMG_6021
There is a fair amount of recession so the sub has room to travel
Date: 04/23/2012
Views: 1312
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IMG_6022
1/2 inch round over on the inner lip
Date: 04/23/2012
Views: 1214
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IMG_6025
1/2 inch round-over on the outer lip of the top of the enclosure
Date: 04/23/2012
Views: 1252
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IMG_6029
Marking the cut-out for the speaker terminal
Date: 04/23/2012
Views: 1000
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IMG_6030
Cutting it out
Date: 04/23/2012
Views: 983
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IMG_6033
Free-hand routing the recession for the speaker terminal
Date: 04/23/2012
Views: 1317
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IMG_6035
Speaker terminal nice and recessed
Date: 04/23/2012
Views: 1099
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IMG_6036
Speaker terminal screwed into place
Date: 04/23/2012
Views: 1011
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IMG_6039
Cutting out the 2nd piece of MDF
Date: 04/23/2012
Views: 1143
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IMG_6047
Laminating it to the top piece
Date: 04/23/2012
Views: 1274
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IMG_6050
Ample coating of fiberglass resin on the back of the enclosure top
Date: 04/25/2012
Views: 1126
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IMG_6051
Making sure to fill in any gaps around the speaker terminal cup with plenty of resin
Date: 04/25/2012
Views: 1159
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IMG_6052
The Bose factory amplifier (removed from under the front passenger seat)
Date: 04/25/2012
Views: 1408
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IMG_6055
Taken apart
Date: 04/25/2012
Views: 1098
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IMG_6056
Soldering on the amp turn-on lead
Date: 04/25/2012
Views: 1256
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IMG_6058
Soldering on the rear left and right pre-amp leads
Date: 04/25/2012
Views: 991
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IMG_6059
Amp back in the factory location before running the cables under the carpet
Date: 04/25/2012
Views: 918
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IMG_6062
Soldering the speaker leads to the speaker terminal cup
Date: 04/26/2012
Views: 991
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IMG_6064
Test-fitting the enclosure
Date: 04/26/2012
Views: 966
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IMG_6067
Using general purpose caulk to tack the back of the enclosure to the face
Date: 04/26/2012
Views: 1105
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IMG_6069
Trimming back the excess caulk before applying fiberglass
Date: 04/28/2012
Views: 1175
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IMG_6071
Applying 2 layers of fiberglass mat to fix the back of the enclosure to the face
Date: 04/28/2012
Views: 1194
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IMG_6074
Prepping the enclosure for application of bondo-glass
Date: 04/28/2012
Views: 1515
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IMG_6077
Application of the bondo-glass to re-enforce the lip of the enclosure
Date: 04/28/2012
Views: 1310
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IMG_6081
Getting ready to apply fiberglass resin to the inside joint between the back and face
Date: 04/28/2012
Views: 1147
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IMG_6082
Getting ready to spray the back of the enclosure with bed-liner
Date: 04/28/2012
Views: 1217
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IMG_6084
Bed-liner sprayed onto the back of the enclosure. It adds some grip and looks better than the bare/rough glass
Date: 04/28/2012
Views: 1207
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IMG_6091
Leads coming off the factory Bose amp ran under the carpet under the passenger seat
Date: 04/30/2012
Views: 1231
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IMG_6094
Eclipse XA1000 mounted under the drivers side front seat with wires all ran under the carpet
Date: 04/30/2012
Views: 1466
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IMG_6095
Masking off the top of the enclosure for priming
Date: 04/30/2012
Views: 1389
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IMG_6097
Shooting the first coat of primer
Date: 04/30/2012
Views: 1456
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IMG_6099
Shooting 2nd coat of primer (black)
Date: 04/30/2012
Views: 1410
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IMG_6101
Removing the foam support from the carpet using a bread knife (worked really well)
Date: 04/30/2012
Views: 1538
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IMG_6103
Support removed with very little damage (can be put back on later)
Date: 04/30/2012
Views: 1294
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IMG_6104
You can see the glue on the underside of the carpet
Date: 04/30/2012
Views: 1394
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IMG_6108
About 10oz of poly-fill
Date: 05/01/2012
Views: 1265
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IMG_6109
The new Polk MM1040DVC Sub
Date: 05/01/2012
Views: 1346
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IMG_6115
Shot with textured paint with the Polk sub fitted. I had to route out an additional 3/16 of an inch all the way around as it's outer diameter was larger than a standard 10" sub's dimensions
Date: 05/02/2012
Views: 1377
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IMG_6116
Make-shift jig to reduce excess height from the Polk's plastic grill
Date: 05/03/2012
Views: 1260
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IMG_6117
Trimmed down ring
Date: 05/03/2012
Views: 1078
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IMG_6123
Finally installed where I can put my back carpet in
Date: 05/03/2012
Views: 1120
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IMG_6124
The grill looks nice, but adds considerable height
Date: 05/03/2012
Views: 964
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IMG_5968
Carpet back in
Date: 04/15/2012
Views: 4942
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