I'm going to use this thread as a build log...it will include failures.. triumphs.. final shots... even if i end up effing up my Z you will get to live it with me.
Any Questions?

3/2/08

Mocking up with paper...




Now with card board




Tracing out on MDF.. I'm using .5" MDF because the box is small, so I'm not concerned with the strength.


Cuttin'm out..


Looks pretty good, eh?


Wait... something looks fishy...


W...T...F....Guess I will have to nix that piece and use fiberglass there.


Mocking up base in paper..


Cut out and test fit...


Oh lord... how did I miss that gap too.. WTF!?!?!?


Calming myself down...


Guess I will do that side with glass too.. new base with paper..


Traced onto MDF...


Cut out hole for terminal cup..


Terminal cup test fit.. looks good....


Cut out...


Test fit...


Let the masking begin...one layer of tape..


Aluminum foil over the tape.. cheap insurance!


Tape over the aluminum again.. sometimes the foil sticks to the resin and its a pain..Is this overkill on masking? Probably.. but the way I figure it the primary objective here is not to make a sub box, its to not eff up my brand new car.


Thats all for now.. a few more later today and probably over the next few weeks. I gotta run to wal-mart for some drop plastic to mask off the rest of the interior so i dont get resin everywhere.

 

OH this is going to be GREAT!!...subscribing

 

now need to make one for both sides and we can make millions

 

Waiting for more pics.

 

looks good...you are puting release on the tape right?

also, make sure oyu let the glass dry completely, i'd suggest overnight, after you do the final layer on it, to prevent it from warping and not fitting right.

good luck!

b

 

WOW this is gonna be good.

 

damn, nice work so far.

 

I think tonester did a similar mold for both sides in these locations but in FG...subscribing. If you don't buy release spray then wax would work as well.

 

Thanks Bing! I just use petroleum jelly instead of release wax...
Thats a good tip on the curing.. I will do that. I think I learned the hard way the last time i did this (3 years ago), and I had forgotten! I would have repeated that mistake so thanks!

 

update 3/2/08 Afternoon
These pictures will also be added to the original post so people dont have to hunt all over the place.

Base in place..


Luke.. I am your father..


Mixing up a test batch of resin...


Covering up my nice carpet.


It was here that I decided to hose you guys because I didnt want to try to juggle the glass, resin, acetone, and camera while wearing gloves. So.. I hosed you. I promise it will get better when its out of the car.

Here is the run down though. My first enclosure build some time ago, I used chop mat as per most tutorials on the web... this time I used an 8oz cloth that was woven loosely made to follow curves -- I picked it up at a local fiberglass shop. I think this might be the way to go now.. it was a little tough around the edges where it frayed a little, but working with chop mat is like dealing with frays all over the place.

I cut three oversized pieces roughly the size of the three sides i was covering.. painted some resin over the tape, layed the cloth over it and then saturated it with resin using a disposable brush.

Here is what it looks like now.. i'll let it cure over night as per Bing's tips.


And a gratuitous shot of my new (to me) evo-r shift **** and home depot ball **** shank ***** washer finisher..


Comments?

 

update 3/2/08 evening
These will also be added to the first post so people dont have to hunt all over for pics.

Another layer...


And another...This is the last one today.. I'll let it cure and then try to take it out in the morning before work.

 

also subscribing....looking good.

 

UPDATE 3/3/08 Morning
These pics will be added to the orginial post also.

I took the mold out..the part that follows the strut bar is still a little flexible and im a little afraid it might warp when I add layers to it..maybe just add one at a time? any thoughts on that bing (or anyone else?)... Other than that it looks good to me.


And here is the Z again... still looks virgin.


More today hopefully.. I am already running late for work! At the least I will get most of that tape off, hopefully do some trimming too.

 

Do it one layer at a time.

 

Dang... This is a pretty costly project right? I know fiberglass materials aren't cheap, Looks like a sweet start...I'm subscribed - Good luck sir

 

i usually do a bunch of layers at the smae time, somstime as many as 6-7, and all in the car on the initial processor.

this way, when its dried, its solid and completely in shape. i almost never add glass to anyhting outside the car, cuase it will dry and put stress on the piece differerntly and cuaes warping...

somteimes in subboxes, a slight warpage isnt too bad, but for small things like dash pods, even a tiny bit of warp make sit look bad...so i am **** and do it all in the car, always

b

 

Fiberglass is pretty cheap. Check out fibreglast.com.

 

its pretty cheap... just find a local shop that sells it... you'll spend a fortune using the crap that home depot sells.

 

the cost of glass has resin though, over the past year or so...but its no where near as bad as the rise in CF costs...yikes...

keep us updated

b

 

UPDATE 3/3/08 Afternoon

I had to swing by home during my lunch break, so i stripped some of the tape off. I guess I should have heeded Bing's warning and used mold release wax, can't get the rest of this tape off. Oh well, what can you do. I think I'll drop by the shop later this evening and pick up more resin and some chop mat, this cloth isnt building up as stiff as i would like.


And in the car...