Project: Sub Box for the Hawk V2

[The_Hawk]

Following on from here:
http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=15247

Seems there are a few minor differences between a 95 and a 96 VR6 in the boot space. After a little swearing and with hind sight being a bitch and all, V2 is well underway.

The key is preperation:
http://www.vwwatercooled.com.au/forums/images/imported/2008/05/IMG_0339-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/IMG_0340-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/IMG_0343-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/IMG_0344-1.jpg

The frame and front will be remade this week and hopefully I will get my bass end back soon :D

Once again Louis makes the whole thing look easy. It funny though, I wouldn't have thought about giving this a go, but I'll pull apart an engine... go figure.

[The_Hawk]

For anyone that is interested and has a Mk3 and is in Sydney I'm sure Louis will be open to offers for V1, although it's highly recommended to test fit it first, just to be sure. If it fits, a 12" Sub never looked so good :D


It's all complete.
Here is the run down of the box:

The back wall
The wall is layered with 4 coats of 400G choped strand of fibre glass.

Skeleton
2 inverted L shaped 18mm ply wood and 12" ring.
http://www.vwwatercooled.com.au/forums/images/imported/2008/04/DSC06693-2.jpg

Base
MDF base with 4 layer for 400G fibreglass.

Surface
Cotton material with resin with another 4 layers 400G fibreglass.


Stablity
The tight fitting of the fibreglass mould is aready very stable but it is also reinforced with anti slip mats on the base.
http://www.vwwatercooled.com.au/forums/images/imported/2008/04/DSC06701-2.jpg

Terminals
It is secured inplace with silicone and glassed over to prevent air leaks.
http://www.vwwatercooled.com.au/forums/images/imported/2008/04/DSC06699-2.jpg

Volume
The bubble test shows ~24-26L.


Carpeting
http://www.vwwatercooled.com.au/forums/images/imported/2008/04/DSC06706-2.jpg

[Soundofav6]

Hey arron, thanks for the advertisment. :)

The Box is complete, just need your car for few more hrs and carpeting.

[rayray086]

Very nice, top job by Louis again!

[The_Hawk]

PM coming your way Louis, otherwise, if your interested, for about $30 worth of gear I can fix your boot light like this:

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/_MG_7304-1.jpg

[Mrk_Mickey]

That anti slip mat fabric looks very farmiliar Louis!! ;) Nice job mate, you're definitely going to be recommended to anyone who asks me!

[Golf Loon]

Sweet Job man, 12" Sub and a useable boot. Thats hard to achieve. NICE.

[DubSteve]

Sweet Job man, 12" Sub and a useable boot. Thats hard to achieve. NICE.

Awesome work Louis, I have only a 10" and no boot haha:D

[Soundofav6]

[QUOTE=Mrk_Mickey;156829]That anti slip mat fabric looks very farmiliar Louis!! ;)QUOTE]

;)

Thanks for your comments guys.. photos later tonight.

[The_Hawk]

And the finished product...

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/IMG_0370-1.jpg

Nice.

[ScienceVR6]

jeeze its hard to hide those speaker wires under the shelf aint it?

I am ging to try and trim the under side in black carpet, over the magnets and speakeer wires to try and hide them on mine. If it works, i'll post up a how to.

[Lorenz]

Think its time you start mass producing some more of these and flog em off. Id be very keen for one :)

Might even have to give this a go myself soon! You make it look so easy!

[The_Hawk]

jeeze its hard to hide those speaker wires under the shelf aint it?

I am ging to try and trim the under side in black carpet, over the magnets and speakeer wires to try and hide them on mine. If it works, i'll post up a how to.

I planning on heat shrinking the wires and tieing them back to the parcel shelf (or the child restraint bar). The only thing to remember is that you want to ensure the wires still have a point at which they can be unplugged so if you need to take the tray out you can. Nothing like building something in so neatly, then having to rip it out :)

What I'm thinking is to tack all the wiring to the shelf, run it along the edge, then have a single plug at the side. I will also post up some results when I get to it.

[bboyskidz]

Oh man I have so many questions...

what are the costs involved with getting some fibreglassing products?
where would be a good place to get them on the coast?
what would i need to do something similar the opposite corner of the boot?
is there any issues with drilling holes in the side of the boot (through the metal) to hold the unit in place?

if someone could answer these questions I would be very grateful :D

[Soundofav6]

Oh man I have so many questions...

what are the costs involved with getting some fibreglassing products?
where would be a good place to get them on the coast?
what would i need to do something similar the opposite corner of the boot?
is there any issues with drilling holes in the side of the boot (through the metal) to hold the unit in place?

if someone could answer these questions I would be very grateful :D

Hey Lochlan
1. Prices of fibre glass really depends on the job, Bunnings sells fibreglass for $25 / meter square, but you also need resin, catalyst, lots of brushes and gloves, adhesives, and good quality tape. All that would add up to $100+ for project like this. unless you can find a wholesaler for cheaper but you still have to buy in bulk.
2. No idea, try bunnings first.
3. You wouldn;t need to do anything unless you want to dynamat, but thats very optional.
4. You shouldn't need to drill any holes, usually if the mould is well made, it should sit in place.

[rayray086]

Yellowpages helps a great deal. There are quite a lot of fibreglass shops around the Sydney metro area so I reckon there should be no problems finding one in the Central Coast. Most boating shops should have them too.

[99gti]

Waren Hearne Yachts at Kincumber. You would probably be able to get some scrap of Greg Normans boat to make your box out of :D

Biase Marine on Pacific Hwy/Central Coast Hwy @ West Gossie should have some too...