- 1). Mask off the panel area that you are assigning for subwoofer installation. Press the aluminum foil into the curves and contours of the panel or trunk space. Seal the edges with masking tape.
- 2). Put on the gloves and mask. Wet the polyester fabric thoroughly with the resin and paintbrush. Press the wet fabric into place, sticking it to the foil.
- 3). Allow the fiberglass resin to harden. Repeat adding layers in the same manner as the first until the desired thickness is achieved.
- 4). Pop out the cured back panel of the enclosure. Cut the wooden dowels to the target mounting height of the W3 woofer. Glue the wooden dowels to the inside base of the enclosure.
- 5). Glue the wooden mounting ring to the tops of the dowels. These rings are found at online speaker building outlets, pre-cut for common speaker sizes.
- 6). Lay a piece of polyester fabric across the mounting ring, large enough to leave at least 1 inch of excess material on the back of the rear panel of the future enclosure.
- 7). Staple the fabric to the upper portion of the mounting ring. Stretch the remaining fabric around the back and staple it in place, pulling out wrinkles as you go.
- 8). Apply the resin repeatedly, until the upper surface is wet. Allow the upper layer to dry, then repeat the process in the same manner as construction of the back panel.
- 9). Cut out the center of the wooden mounting ring, prior to the resin fully curing.
- 10
Apply body filler to any uneven areas of the upper portion of the enclosure as desired. Sand smooth with the 60-grit sandpaper. - 11
Drill a hole in the back of the enclosure just large enough to accommodate the speaker wire of choice. Seal the gap around the hole with silicone to prevent air leaks.
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