2016 Porsche Macan S - stealth SQ build

[Ge0]

Day 2


Glue in re-enforcements in corners



Plan out the top baffle





Cut cut cut







I need to trace this outline but did not have any tracing paper





Transfer outline to next shape.



Cut the next stack in the baffle



To be continued...

Ge0

[Ge0]

Day 2.5


Oh boy! I fits like a glove in my subfloor



Finish up the stack






Now attach the top baffle. More rain and lost daylight. Move operations indoors again







After all this work the d@mn subwoofer better fit...



WOW! I could have went with a deeper 10" sub. But, I'm happy with my SD4 for now.



Refueled. Time for sanding.



All done sanding. Now what???


To be continued...

Ge0

[Ge0]

I have been in such a rush to get this sub enclosure done before cold weather sets in. I haven't had time to post. Anyway, nearing the end of this fabrication job. I sure hope this thing kicks as much a$$ as I designed it to.

Get supplies ready:


OK. Let's fiberglass the wooden shell with an outer layer of cloth that will wrap around it's strange contours. This is a twill cloth purchased from US Composites:


Staple it into place so it doesn't move around so much while applying resin:







Start dabbing in the resin








It took an hour and 32oz of resin to completely cover the first layer of this box. Now it's time to dry...

No, there is no problems with my butt. I learned this trick from Glassman a few years ago. Apply it liberally to your arms to close up pores. That way fibers don't get in. Also, apply it to your hands to make taking latex gloves on and off easy.



To be continued...

Ge0

[Ge0]

Now for some cleanup work now that the resin has dried.






This sucker came in real handy when cleaning up the edges:



Sand down sharp edges so I can handle the enclosure without getting pricked or cut.



Glue in one last cross brace to add strength.



Now prepare to glass the inside of the enclosure. Here I chose a bi-axial material from US composites. This is a cloth with mat fibers sewn into it.



Cut up some workable sizes in advance so you don't need to screw with cutting while your hands are all sticky and gooey from resin.



I found using this glass dish to be priceless. Lay a piece of material in, fully saturate it, then lay it on your work piece. Trust me. This is MUCH better than trying to wet the cloth out inside the work piece. You will add a little more resin onto the cloth once you lay it in. But, since it is already saturated you don't need to work as hard. Make sure you are wearing rubber gloves. Working the cloth in place by hand is a must to get it to lay flat. Use your brush to tamp out any air bubbles.



First 16oz of resin laid





To be continued...

Ge0

[Ge0]

More glassing and building up 4 layers:












All done laying fiberglass inside. Now take the cordless edge sander to knock down sharp edges inside the enclosure:



I decided to add Bondo Glass (short hair fibers) to the inside corners of the enclosure where the baffle meets the box. Just to further strengthen the bond. I also placed Bondo Glass over sections inside the enclosure where I cut out air bubbles and left pockets in the material.







I also added some dowel rods while I was at it to strengthen the baffle.


To be continued...

Ge0

[Ge0]

Now time to apply a finish to the outside to make it look nice and smooth.

I decided to use Evercoat body fillers because they are supposed to be far easier to sand than good old Bondo. I started with a quart of Rage at first but soon ran out. So then I bought a gallon of Rage Ultra.

NOTE: Make sure you knead and squeeze the hardener tube prior to use. Otherwise when you go to apply hardener a bunch of liquid will ooze out. You need cream not liquid. I found this out the hard way. My first layer took 2 days to dry vs. 20 minutes.

Sand Sand sand.




Applying the first batch:



Sanded down the first pass. However, there are some places that need more material. A 2nd coat will be needed.



The ultra goes on thicker than the Rage. However, it is self leveling to a degree which will make sanding easier.



Sanding down the 2nd coat really made the enclosure take shape and feel smooth. Note, I sanded the corners by hand to make sure my power sander did not remove too much material:



I forgot to take a photo. But, I glued the top step baffle on after the first sanding pass. I then feathered it in on the second body filler application.







I could have called it quits here. But, there were a few voids that were bothering me. So, one simple 3rd pass of filler. It was getting dark and cold. So, I will need to wait until tomorrow morning to sand this and finish it off.



Next up. Apply glazing putty to any remaining pin holes then prime and paint.

To be continued...

Ge0

[BigAl205]

Awesome progress! You should be receiving a special CAJ care package today.

[Ge0]

Awesome progress! You should be receiving a special CAJ care package today.

Cool. After going through all this mess to make a darn subwoofer enclosure I certainly gain the title Car Audio Junkie.

Ge0

[SmallSoldier]

Great work Ge0! Loving the attention to detail and taking a few cues as inspiration for my build.


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[DavidRam]

Looks great, man!