I started working on my new system project this weekend and here's what I've got done so far. (sorry for the crappy cell phone pics, will have better ones later)

Stripped trunk clean and dynomated the entire trunk
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Masked off each corner of the trunk for the Fiberglass molds
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Popped the molds out
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Built the amp rack for the following:
Kenwood DTS processor, Sirius Tuner, Cap, Alpine PDX1.100, and Alpine PDX4.100
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I already have Infinity Perfect 6.1 in the front, will be placing perfect 6.1 in the rear with custom tweeter pods. I removed the 6x9s out of the rear deck for better bass flow.

Once the sub boxes are finished, I'll be placing my trusty 8 year old Infinity Perfect 12.1 in each corner of the trunk. This is my first true custom install (Fiberglassing) So things are moving a little slower than I'd like. I have about 3 layers for fiberglass down on the boxes and am working on the rings and ring mounts for the boxes. So far I have about 20 hours of work into the project.

My question is for those who have worked with plexiglass in the past, what do you cut it with as I want to make plexiglass grills for the subs and for the amps.

 

A table saw with a carbide tip blade. The more teeth the better.

 

looks like great work, can i ask you a couple questions?
So you can just put blue painters tape all over and fiberglass right over it, and it works fine?
What kind of fiber glass are your used? the kine with the fiber layer? or some jelly resin?
thanks

 

Looks good. I'd love to see larger/better photos.

 

Looks good. For cutting plexi glass I would use a jigsaw. I'm with Gilley on this can we get some bigger pics please!

 

Yes, I'll get better pics up soon. I just pick up a couple of quickies from my phone.

As to the person who asked about glassing over the tape, well, yes and no. I Put down a layer of tape, then a layer of foil, then another layer of tape. I then sprayed Pam (the cooking spray) over the tape and then put down three coats of pure resin (not the jelly crap). I let it harden for about 6 hours then popped the molds out of the corners of the trunk. I put the initial layer of glass down with woven cloth, which seemed to work really well, now the remaining layers I'm going with mat (mat is a lot heavier in weight than the woven cloth).

This is my first time working with glass, I just read some tips on this site was well as fiberglassforums.com

I'm making a circle jig for my jigsaw, guess another trip to home depot to get a good blade for cutting the plexiglass.

 

Good luck and keep us updated. Glassing is a lot of work and takes a lot of patience. I glassed one of my old show cars and it came out pretty good to my surprise.

 

Patience is true. I've been working on them 4 days now and I only have 4 layers of glass down. I need to sand them really good before I do my next layer. I took a bunch of pictures but they're on my digital SLR and I don't feel like taking the time right now to resize and compress the pictures which are currently 29 megs/picture.

 

Haven't had time to do any further work this week, but I plan on getting a lot done this weekend including the better pics.

 

Well, I got a little farther today.

7 layers of glass and resin


Positioning the Ring


Stretched the fabric over


I'll be working for another 8 hours on it tomorrow.

 

Very nice work so far.

I worked on quite a few show car systems a few years back and have been too lazy to do another one for my car. Maybe this summer.

 

I've got two more layers of glass to put down tonight and tomorrow drill out two holes for the speaker terminals, wrap it with carpet and install it. I can't wait!! I wonder how long the resin smell will stick around. After this one is done, then its time to finish the driver side box, then the cover for my amp rack.

 

Here's after 7 layers of glass, gonna lay down one more and test fit it again tonight.

 

I've never had great success with using a table saw to cut plexi before. The thing to look out for is the friction. Too much friction will cause the plexi to melt rather than cut, thus creating a horribly messy edge. I have generally used a jig saw and followed a straight edge that is clamped, or simply score and snap.

 

Well, I got the first sub done. Its on the passenger side and here are the photos.

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