JohnL71RS’s Project restart…..

Discussion in 'Project Progress' started by JohnL71RS, Nov 11, 2010.

  1. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    It was a very time-consuming task to build the sub-woofer box with fiberglass. First off, my initial calculations wouldn’t work. After building a template, the angles were all wrong. Adjusted and made different style template with better luck. Once I was satisfied, I started cutting out some 1/8” plywood as my base box. I used some corner molding to nail it all together. Also put in some boards to flatten up the centers and edges. Then I applied the first layer with only 1-pound mesh. I then went back to store and purchased 1.5-pound mesh and more resin. I tested the fit after the first coat. I had to trim the top corners to get it in easily. I also had to cut the top/right because it was hitting the rear speaker. I put a small notch in the rear angled panel for the jack bracket welded to the trunk floor. Here are some pics.

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    During drying times, I finished the resin and filler on all my trunk panels. Then I cut out the holes for the grills. I put in the box and placed the front panel in to see my concept.

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    Here is a pic of the port I made.

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    I did two coats of 1.5 mesh on the entire box, except the front. I then proceeded to put mesh on all the inside corners and fiberglass in the port.

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    I did cut out the front panels. The passenger side is made of ¾” birch plywood. I wanted something thick to screw in the speaker. The other side is ¼” plywood. I will be putting on two coats of fiberglass on the ¼” and only doing fiberglass on the edges of the ¾”. Thanks for checking out my progress.
     
  2. Double R Restorations

    Double R Restorations Veteran Member Gold Member

    2,624
    18
    Jan 11, 2002
    VA
  3. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    More trunk work last week. I put in the front panels and fiberglass’ d the inside covers.

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    I then proceeded to add 2 heavy fiberglass coats over the ¼” side of the front. I also put 2 or 3 coats on all the outside corners of the ¾” section for the speaker. Here is a pic in the car after sanding the outside and inside.

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    Next was to start trimming in all the panels for a loose fit. This would allow me slack till I put in the carpet. I also wanted to see how the panel looked with the sub box behind it. Here are some pics.

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    I did remember that I had to add to the top corner of the rear panel. After accomplishing that, I forgot that I had to add to the driver’s side because it was too short. So back to filling in again. Unfortunately, the panel fell and broke the small piece of fiberglass section I bend over the lock. So, I repaired as usual.

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    Finally, I got to put in the carpet and try the fit. I was able to lift the sub box and put the carpet under it. I trimmed the carpet around all the clips and started installing panels. The side panels only needed slight trimming. The front panel was troublesome. It took many times to get corrected. Currently, I am working on the rear panel and filler piece of the gas tank neck indention. Anyway, here are some pics with the carpet in.

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    I will cut off all extra aluminum on the braces on all panels, finish up trimming in the pieces and getting them ready for leather. I also need to get some aluminum plate to make the grills. I did get in my perforated aluminum. Once all the grills are made, then I can router out the outside of the panels holes to accommodate the mesh. Then I will be able to wrap in leather. Lots of small things to do this weekend, but a hurricane is coming my way and I have preparations to do for that. Thanks for checking out my progress.
     
  4. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    thanks,
     
  5. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    I know my post lately are about my trunk enclosure, but I couldn’t find any details on how to do this on other sites. Plus, it’s on a Camaro. I was able to get some work in this weekend even though the hurricane came on bye. It didn’t pass too far from me, but the rain and winds weren’t that bad on the west side of the storm, so I got a little wind and lite rain.


    So, I cut out all the inner sides of the channel I used for stiffeners and backing of the grills. It doesn’t sound that bad, but it took many hours and patience. Here are some pics.

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    Later on that night, my friend came over and wired up the flat EQ and new radio.


    Sunday was devoted to making all the clips to hold in the panels and brackets for the sub-woofer box. I then finished trimming in all the panels. Next, I had to epoxy all the clips, bolts and brackets to the floor of the trunk. I really need to keep the sub box bolted in tight. The panels will all be held in with Velcro on aluminum clips or cut angle.


    Then it was time to cut out the holes for the radio and flat EQ in the section on the center console. This panel will be covered in leather later. These holes had to be cut as tight as possible. Once I got the holes cut and trimmed in, I epoxy’ d the radio bracket to the aluminum panel and epoxy’ d in all the brackets and clips. Slowly I am getting all this done. I will probably pickup a new sheet of 1/8” aluminum this week so I can cut out my grill covers. Here is a pic of the console with the radio and eq.

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    Thanks for checking out my progress.
     
  6. Thrust!

    Thrust! New Member

    21
    2
    Sep 18, 2017
    Nice! What part of New Orleans are you in? I live in Slidell
     
  7. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    I live on the Westbank in the lower section of Marrero just before Crown Point and Lafitte.
     
  8. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    I started on the grills for the trunk panels. This is a very slow process, but the outer rims are cut out. I still have to epoxy the studs and perforated metal on. Also, I need to sand and clear coat them. That is the task for this weekend. Here is a couple of pics.

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    Thanks for checking out my progress.
     
  9. JohnL71RS

    JohnL71RS Veteran Member

    1,606
    19
    Apr 12, 2010
    Marrero, LA
    I worked on the panel grills this weekend. I had to clean up all the grills with sanding all the edges. Next was to overlay the grills over the panels and drill a small dot so I could know where the bolt goes. Afterwards, I had to lay out all the bolts and then epoxy all the screws to the grills. I had over 70 screws. Once the epoxy dried, I put the grills on my perforated metal and laid out the metal. I must say that I bought a metal nibbler for my drill and it was the best investment yet. It went through the metal like butter and was very easy to use. There was a lot more trimming once all the pieces where cut out.


    Next was to put the grill on the panels. Well I knew the bolts wouldn’t fit exactly so I had to drill out the holes in the panels and ream the holes as needed. Here is a pic of the grills. I still have to sand all the pieces, epoxy the perforated metal to the rings and then clearcoat them.

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    Thanks for checking out my progress.
     
  10. Jas0n

    Jas0n Veteran Member Lifetime Gold Member

    953
    3
    Apr 27, 2010
    Verona, ITALY
    Absolutely amazing! You ended up having a beautiful trunk full of sick (and loud) stuff!
     

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