EM TuningAH Fabrications
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  1. #1
    billybravo's Avatar
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    been very busy building new sub box

    Hello all

    Well i dont know if you remember my old install i was happy with it but the whole lot was very heavy and i got sick of not having a boot.



    Well i ripped all that out and going with just one 15" this time in a custom glassfiber box to the left hand side of the boot

    this is how ive been going on im still a long way off but i will update the post as i go.

    The big tape up this took some time





    The first of many layers of glass














    i will update with more info when i get a bit more time..

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  3. #2
    joost's Avatar
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    Did you not have the PC on that side before?
    Justin

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  4. #3
    Broken Byzan's Avatar
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    Is that box going to be big enough for a 15?? I have a 10 in the same spot and i am running it at the small side but wadded to compansate,around 20 ltres mine is

  5. #4
    billybravo's Avatar
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    im not sure where im going to put my pc think i might hide in under the dash.

    as for the box im hoping that its kinda of the same area as my old one as the ring which holds the sub comes out a long way. i will fill with water when im done to make sure there isnt any leeks and that way i can find out how many ltrs it holds.

    cheers

    craig

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  6. #5
    PhilR's Avatar
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    best way to ensure no leaks is to "milkshake" the inside of the box.

    Basically add a tub of filler to about a litre of fibreglass resin (its not an exact science !), stick plenty of resin hardener in and mix it up.
    Then masking tape up the subbox especially at any joints fill the box up with this milkshake and slosh it all around the box till it starts to thicken and stick then set. guaranteed no leeks !

  7. #6
    billybravo's Avatar
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    cheers dude i will try this thanks

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  8. #7
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    well i got the front on this morning still got to gt a few more layers of glass on top and inside if i can.

    heres some more pics








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  9. #8
    PhilR's Avatar
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    cool, what material have you used ? is it fleece ?

    i have made boxes using fleece resined than strengthened with just the milkshake mix described rather than glass fibre-ing the fleece too

    Fleece is cool because it soaks up loads of resin and only costs about a pound a metre too !

  10. #9
    billybravo's Avatar
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    yeah mate its fleece and it did soak up a hell of alot of resin im happy with the way things are going

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  11. #10
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    Hi guys,

    I don't wanna sound like a smart a#s but the volume of a sub box has to be calculated quite precisely and the final volume will depend if you are making a reflex or a closed box. If you are only looking for the "visual" effect of a sub, whatever but bare in mind that you won't get the real capacity of the sub if you do not have the proper box which is made specifically for the sub you want to install.

    My 2 pennies of the day...

  12. #11
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    Fook me good work! Wanna tidy my install?
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  13. #12
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    yeah thats a good bit of info there mate

    and as you say numbers do have to be calculated i did this on my old box and ive made a few for the same subs in the past thats why ive gone by eye on this box the box isnt any smaller or bigger than the box i used to run this sub in.

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  14. #13
    billybravo's Avatar
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    Well i did the milkshake thing on the oldside like you said and f==k me that was messy lol

    ive got to be back in work tomorrow so i will be doing bit and bats but i should be updating later on in the week

    still got to put the milkshake on the inside will do this tomorrow night









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  15. #14
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    YaY Milkshake! I want a Vanilla one!

    Good job though, I hardly see anybody making their own sub with glass and milk!

    Good luck, keep us posted!

  16. #15
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    Billy that looks great mate, keep it up !!

  17. #16
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    Quote Originally Posted by A4NA18
    Hi guys,

    I don't wanna sound like a smart a#s but the volume of a sub box has to be calculated quite precisely and the final volume will depend if you are making a reflex or a closed box. If you are only looking for the "visual" effect of a sub, whatever but bare in mind that you won't get the real capacity of the sub if you do not have the proper box which is made specifically for the sub you want to install.

    My 2 pennies of the day...
    Get the size wrong with a ported box and you're not gonna have any luck. But a sealed box isn't so bad if the size is out a little. Bigger than required will get a bit boomy normally but smaller than required will probably give a tighter sounding bass, and the sub will handle more power

    Nice work there billy. Check the sides of the box are solid, and dont have any flex in them, if they do then slap more FG and resin on the inside of the box to strengthen it up

    Pete

  18. #17
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    cheers dude and what you said is what ive been thinking all along the box wont be ported



    im going to start sanding today and try to get a top coat of bog on will post pics later

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  19. #18
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    once you milkshake the inside it will be nice and thick and probably wont need any more glass. "External milkshaking" is messy but really helps build up the thickness and strength and provides a good surface to prep with filler for paint, thats what i did with mine below resined fleece over an mdf frame then int and ext milkshake its strong enough to hang the sub from the rear shelf

    as for box sizes this is what my 10 is in ! gotta be totally the wrong size but it sounds nice !


  20. #19
    rasA4's Avatar
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    Quote Originally Posted by PhilR
    once you milkshake the inside it will be nice and thick and probably wont need any more glass. "External milkshaking" is messy but really helps build up the thickness and strength and provides a good surface to prep with filler for paint, thats what i did with mine below resined fleece over an mdf frame then int and ext milkshake its strong enough to hang the sub from the rear shelf

    as for box sizes this is what my 10 is in ! gotta be totally the wrong size but it sounds nice !

    Flippin heck that must sound really awesome!!

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  21. #20
    Beerzo's Avatar
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    You'll get at least half a bag os shopping in that boot space now. LOL

  22. #21
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    Oh yeah its useful alright ! my car doesnt have split fold rear seats either so the space behind is useless too, i had planned after I built it to motorise it so it moved backwards into the bootspace and forward into view on demand but im too lazy to rip it all out and get fabricating

    [sorry]
    [/total thread hijack]

  23. #22
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    Nice work phil, loving the craftsmanship wonder how it sounds. Has it added more weight over your previous twin subs? or less?
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  24. #23
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    oh i got as far as preping the first layer of body filler ready for a fresh skim tomorrow.

    to do this i used 40 grit papers and matt black to find the low and high spots of the car filler and also any curves. i trimmed the sub rings again with the router using a trim off bit.










    test fitment






    ive still got a long way to go but im thinking of painting it a nice gloss red or maybe covering it in red suede allicantarra as i can get a good deal on it at 25 pound a meter.

    anyways thats todays work done time for a pint

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  25. #24
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    A pint well earnt mate, where are you gonna put the amps??

  26. #25
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    How about black alcantara with some red detail?

  27. #26
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    Yes alcantara will look far more professional although it may be a bit tricky to fit with such a curvy shape.

  28. #27
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    yeah thats what i was thinking im getting red for the door cards anyway so i can try it out i also want to do all the cream bits like pillers and roof lining in black alcantara then the old seats are coming out for something a little bit more supportive.

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  29. #28
    billybravo's Avatar
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    Quote Originally Posted by mawhitey
    A pint well earnt mate, where are you gonna put the amps??

    that im not sure of as of yet i mite make something for the other side or mount it at the back of the boot as i dont have fold down seats then i will make a cover with a few fans inside so you wouldnt even know the amp was there.

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  30. #29
    billybravo's Avatar
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    Well tuesday was spent sanding and sanding and sanding. i started to coat the box im high build primer today. I want to get a good few coats on to cover any little pin holes in the filler

    but now the box is really taking shape













    Fist coat of high build primer




    TopGear Stockport / Longlife Exhausts /
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  31. #30
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    cool, if you are trimming it in something id stop now, it looks like a good enough surface to trim

  32. #31
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    thinking i might go all the way and paint it now as i would really like a smooth look to it

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  33. #32
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    like your garage billy, looks like you have plenty of room, even with your car in

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  34. #33
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    ok guys this is hard to do but im selling this box as ive gone mad with getting my car as light as i can i cought the stripping bug lol

    offers on the box

    the box should fit any 15" sub and is very strong with around 1.9 air space i will be sad to see it go as i miss my bass but if im ever going to get my car near a ton im not going to do it with a 15 in the boot.








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  35. #34
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    That looks excllent and loads of work gone into it. Shame your selling it after that but the stipping out can get crazy i know i did the same with my Silvia.
    A4 Avant project now started ! see this thread ! http://www.audi-sport.net/vb/a4-s4-forum-b5-chassis/43296-bit-project-going.html
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  36. #35
    billybravo's Avatar
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    yup it can get mad my i stripped all my aircon at weekend i will defo miss the bass but if im ever going to make this car any quicker it has to be done. lol

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  37. #36
    easytease's Avatar
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    very nice indeed. I made a custom box for my 10W7 that came out further then that, and that was only 1cu ft.

    oh, and PhilR, is that two dual mono's i spy there?
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