khguan's DIY Gallery
DIY Custom Subwoofer Enclosure Faceplate
1st January 2008
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This is the very last project for the year 2007, and completed the very last day of 2007 31st Dec. As promised earlier, this is the 2nd fiberglass project which i call it the Subwoofer Faceplate, which turned out quite good.. hehe..

Well, this project is the most time consuming one as there are lots of sanding and grinding involved to get the surface smooth enough. But at last i gave up sanding to perfection, but still look good enough for viewing from far.. :D

Throughout the entire process of making this faceplate, i discovered more efficient techniques which can speed up and make the job much easier to produce better results, which will be useful in coming fiberglass projects.

Next i'm thinking of doing some minor interior jobs. havent decide yet. So enjoy viewing ;) Lots of pics.
First n foremost, cut out the subwoofer frames with rounded edge.
First n foremost, cut out the subwoofer frames with rounded edge.
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Decide on the slanting angle and stick on the support sticks with hot melt glue.
Decide on the slanting angle and stick on the support sticks with hot melt glue.
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Now attach flexible cloth with staples. Here i use 2 layers of cloth for better strength.
Now attach flexible cloth with staples. Here i use 2 layers of cloth for better strength.
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Make sure the staples are stapled closely.
Make sure the staples are stapled closely.
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Alright, here i did lots of strecthing and stapling. Strecth n stretch, with strength.
Alright, here i did lots of strecthing and stapling. Strecth n stretch, with strength.
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Trim off the extra cloth on the unwanted side.
Trim off the extra cloth on the unwanted side.
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The entire faceplate is now wrapped up with the flexible cloth.
The entire faceplate is now wrapped up with the flexible cloth.
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Make sure the cloth is stretched firmly.
Make sure the cloth is stretched firmly.
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Fasten a flat washer with a screw for the mounting hole later.
Fasten a flat washer with a screw for the mounting hole later.
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Washers at each edge of the faceplate.
Washers at each edge of the faceplate.
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Apply resin on the cloth. Make sure the resin damp the entire cloth.
Apply resin on the cloth. Make sure the resin damp the entire cloth.
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Leave to dry. Drying time depends on how much resin catalyst (hardener) is used.
Leave to dry. Drying time depends on how much resin catalyst (hardener) is used.
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Once the resin harden the cloth, cut off the unwanted part, the center hole with a small blade.
Once the resin harden the cloth, cut off the unwanted part, the center hole with a small blade.
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Apply resin and lay the fiberglass sheets onto the surface and apply resin.
Apply resin and lay the fiberglass sheets onto the surface and apply resin.
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Leave to cure and repeat for another 2 layers. Until it is hard enough to sustain the bass vibration.
Leave to cure and repeat for another 2 layers. Until it is hard enough to sustain the bass vibration.
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Here i grind the surface with a disc grinder with sandpaper fitted.
Here i grind the surface with a disc grinder with sandpaper fitted.
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The first step of grinding is a very coarse grinding.
The first step of grinding is a very coarse grinding.
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Now i use 100 grit sandpaper to get a smoother finishing.
Now i use 100 grit sandpaper to get a smoother finishing.
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Surface cleaned with an air gun and ready for putty.
Surface cleaned with an air gun and ready for putty.
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Look what the grinder has done to the surface. That's pretty ugly huh?
Look what the grinder has done to the surface. That's pretty ugly huh?
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Putty applied, leave to dry and start sanding again.
Putty applied, leave to dry and start sanding again.
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Sand with 100 grit sandpaper. Until it is smooth.
Sand with 100 grit sandpaper. Until it is smooth.
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In order to make the uneveness more visible, I sprayed a layer of primer paint on the surface.
In order to make the uneveness more visible, I sprayed a layer of primer paint on the surface.
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Locate the screws that hold the washers.
Locate the screws that hold the washers.
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