Custom subwoofer install

I've had my 2010 pkg II for an entire 24 hours. Now, I'm contemplating starting on a custom fiberglass enclosure for the rear driverside cubbyhole. I've got a JL 10W1 subwoofer, a Rockford Fosgate Punch250, and my Pioneer headunit that I took out of my Blazer when it was traded.

The pioneer headunit has to wait until an adapter plate becomes available to replace the hole that will be left by the OEM stereo. But I can get started on the sub and use the amps high level input lines and crossover to tie into the speakers.

The local Home Depot is out of one gallon resin containers, but is expecting some in on the 4th. This gives me time to design the box, get some MDF supports and bottoms cuttout and workup the courage to pour liquid fiberglass resin into my brand new car. I think I can get close to the recommended .62 cuft out of the cubbyhole area and still be able to open the floorpanel to access the spare tire.

Its moments like these that I realize why I'm not married. Words of encouragement or warning are welcome. Pictures to come as I start this project.

 

Tim, I'm a noob to fiberglass, so all comments are welcome. Why jellied resin?
I've been researching fiberglass construction techniques, hints and tips at FiberglassForums.com They've got some really impressive work there and no mention of jellied resin.

My current best guess is about .5 to .6cu ft out of the cubby hole. I'll know better once I tape it off with some cardboard and measure the volume with some packin peanuts. The recommended sealed box size for this 10" sub (JL Audio 10w1) is .625cu ft. So I should have sufficient space. I want to stay on the driver side because the subwoofer enclosure will utilize the storage space below it as well. Goal is to keep the box in the corner so I can open the main storage area and access the spare tire. As far as filling a trunk, I only need a speaker to replicate the low hz sounds inside the car. I'm not as concerned with volume as quality. So, no I won't be able to compete against someone with a pair of 12" subs in a large trunk box. But it should be sufficient to supply some nice bass to my music.

I took my car down to a local audio shop. The lead tech was ecstatic to get to hunt around inside the new Prius. They said installing a new head unit shouldn't be a problem, but I'm going to have one of the machinist at work custom machine a plastic piece to serve as faceplate as there are currently no aftermarket faceplate adapters available. The tech believes the radio probably uses the same wiring adapters at the 2009. Will find out once I pull the head unit. He also has experience wiring and programming the steering wheel control adapters, so one more problem solved.

I plan on replacing the stock 6x9 and 6.5's while I'm at it. Since I'll be removing some of the interior to run RCA patch cables from the head unit to amps, will probably also beef up the sound deadening in the car to try to reduce some of the road/tire noise. It seems there is quite a bit of bare metal with little or no insulation in parts of the car. It's not really loud, but can definitely be improved.

So, this will probably be a work in progress for a bit of time. Plan on doing the subwoofer box first. Will update as I progress.

 

Nope, nor do I think I'd ever use spray foam insulation in a car. The stuff sticks like adhesive, so its pretty much permanent. It expands, which means it can distort panels.
To stop panels from rattling/vibrating use Dynamat or similar dampening material. To tighten up a panel use double sided foam tape or if you want to fill an interior cavity/gap just stuff it with some polyfill (do not do this in your doors as the polyfill may capture moisture that gets past the window skirt and could then harbor mold).

 

So I went by the store after I got off work and picked up some supplies to get me started. Lesson on the first day. Taping everything up and trying to get it smooth ain't as easy as it looks. Pics of progress below and I'm off to bed as I work 3rd shift.


Target area for box, Drivers side trunk cubbyhole.


Oooooohhhhh... tape.

 

Well started fiberglassing this morning and didn't like the results. My first attempt at fiberglass and like most things was harder than I expected. I think I tried to work to large a section at once. Especially since it is such a vertical surface. So I tore it all out and will be restarting.

Another lesson learned. May try to just fiberglass the bottom tray as a learning tool and to build a base for the box, before restarting on the interior again.

More details and pictures to follow.

 

I don't know many wives that would let their hubbies pour fiberglass resin in their brand new cars.

As far as it being ambitious, I agree but that's okay. As long as I don't screw up the car (I'm putting down plenty of layers for protection), its only my time and the cost of materials I'm wasting. Tinkering, just as I usually do!

 

Just laid 3 coats of fiberglass in the little storage tub that will hopefully become the bottom of the subwoofer box. Wow, this stuff has one heck of a learning curve. Went better than my first attempt, but still definitely need practice. I guess I'll be considering this subwoofer box version 1.0 Will take some pics tonight once it has cured and I've removed it from the tub (with a little luck).

 

We will have to see about that. I really doubt it is something I would do. Shipping has to be outrageous and I doubt my box will be THAT impressive. First things first is to get a decent box made. See pics below of yesterday's progress. Please be kind, first time working with fiberglass, so it ain't extremely pretty. Still have blue tape and foil sticking to it.



Pic of base sitting in the storage bin.


Base sitting in the storage pocket without the bin. I think I'll probably install it with the bin in place so I don't have to worry about losing the bin.