Guide on how to construct a Boot Build

Here is a step by step guide on how to fabricate a custom build.

The example im using is the current build im doing for the C2

1) First things first get your materials together

For mine ive used the Following
- 18mm MDF
- White polar fleece
- Wood Adhesive
- Screws
- Fibreglass matt
- Fibreglass resin
- Hardener

2) Secondly make sure you have the measurements you need and cut the MDF accordingly or a cheating idea is go B&Q and they will do it for you.

3) next thing is to start assembling the frame as shown



Be sure when fixing together to always run wood adhesive along the contacting edges for extra strength and always drill a small pilot hole prior to screwing it together as this will prevent the MDF splitting.



4) Keep going until you have your frame made up mine looks like this



then finally with the subwoofer mounts i suggest using a Router to get perfect cut outs



5) Now you have you frame its now time to seal it if you dont seal it then when your Subwoofers are going the sound will dispere and leak out any gaps distorting sound quality. To cure this i ran a bead of glue along the edges then fibreglassed them.




6) After step 5 you can now stretch the fleece over the frame i insist you use Polar Fleece as its incredibly stretchy and gives awesome curves to the build. You can attach the fleece to your frame using high strength spray adhesive stapling it or you can get a paste adhesive. I used spray adhesive.




7) Now heres the smelly part now you have your fleeced stretched over you have to get it to go rock solid get your Fibreglass resin and add hardner now you have to apply this to the fleece just like painting a wall be sure to cover it evenly and all parts where the strength is needed here is mine. (Apply in a well ventilated area as it very strong and can cause headaches and dizzyness) keep recoating until it its dried rock hard.




after it has fully dried you can either apply filler and sand to a smooth finish so you can paint it or if it going to be covered in fabric there is no need to as it perfectly fine without adding filler.

This guide will continue through to the end of my project this is how far ive got so far

yeah i used silicone as well but thats going on the part 2 but im also gonna stuff it with wadding to and then to cover it all of which i will be doing over this weekend so will be updated shortly

i tried doing a test fit and i couldnt get it in cus the shape of my door cards was stopping it so i got to take the rear cards out to get it in i made it so tight so i wont have any gaps down the sides