After searching for some time for a sub/amp enclosure I decided to make my own. I had to learn as I went along. Read many articles online and watched a few videos. I wanted it to be clean looking, fit into the hatch interior without any cutting of the factory plastics. Removeable except for disconnecting the wiring. Started by making a flat platform for the sub/amp box to set on. Used 3/4 mdf and supports underneath in the well. Then I started on the actual enclosure itself. Framing on the back of the mdf sheet and side trim pieces that go around seat belts.

 

Next came the subwoofer rings made out of 3/4 mdf. I bought a jigsaw cirle cutting kit from home depot. The subwoofer manufacturer gave exact dimensions the rings needed to be. The capacitor box was made with some 3/8 thick wood. The holes in the top of the capacitor box are for the power and ground leads as well as the outputs to the two amps.

 

The framing for the sides and back came next. Also the amp box was added. You have to leave room underneath the board your amps mount to for wiring and enough room to be able to lift the amps up for easy access in the future.

 

Next came the trim pieces that needed to be cut to match the contour of the hatch interior. This part was very time consuming and pain in the butt to get right. I got some cardboard from work and made templates first so I wouldnt screw up the actual wood. There were five pieces. Left and right sides and the back below the hatch pull down. I cut these pieces oversize on the outside edge. Had to sand to match contour of interior plastic. Makes for a tight clean finish after covering. In the second picture when its in the car you can see were I used bondo to make the transition smooth as well as for strength.

 

Onto the fiberglass and resin stage. I have never worked with fiberglass so it was a learn as I go. Maybe could have done this different but it all worked out in the end! Started by stretching my resin cloth over the portion I wanted to fiberglass. I used 3M trim adhesive and a staple gun to hold it in place. The contour between the subwoofer rings and the capacitor box was straight so I decided to staple it down in 4 places so I could get the effect (look) I wanted when finished. Then I took fiberglass mat and covered over the 4 indentations. Make for a smooth finish.

 

Did not get any pictures of the multiple coats of fiberglass. Its a slow process applying then sanding. Cut your holes out were the subwoofers go as well as the top of the capacitor box. Now it was time to cover it with black carpeting. The local sound shop sold subwoofer enclosure material by the foot. After stretching the carpeting it was obvious there was going to be a problem were the indentations for the seat belt came out. Material just wanted to bunch up and look crappy. Ended up cutting the wood corners for a more even radius. Using spray trim adhesive to hold the carpet. I started at the back and worked my way forward to were the amps were going to be. A couple of things I learned the hard way not to do. To much spray adhesive will soak thru your carpeting making it come out white after it dries. Also stretching carpet to hard, forcing it around contours is not good. Finish covering the rest of the box. The only seams were at the bottom of the box (2 of them) were the carpet made a 90 degree turn. If you get any glue onto the carpet you can remove it with brake fluid dabbed onto a shop rag. Lightly brush over the glue and it comes off.

 

Next I drilled the subwoofer rings with a template (gasket) provided by the sub manufacturer. Prefit subwoofers with screws. Also Covered the inside of the capacitor box with carpet. Next came all of the wiring. I ran the power down the passenger side and the RCA and speaker wire down the drivers side. Not going to go into any more detail on wiring. Too lengthy. The board the amps go onto had to be covered with carpet and drilled for mounting and wiring pass thru.

 

Here is the finished product. The amps and subs are Audiobahn. The head unit is a double din Pioneer touchscreen DVR. I inverted the subs for the look as I show this car. Also didnt have to have the cap but it added to the design overall. Inside sub box volume was 1.5 per sub if I remember right. Subs clear the hatch glass by about an inch in this design. Make sure you check and double check clearance issues. Hope you like it.

 

Great work!