I had all day to get some work done! The new plan is to ditch the spare tire and create an amprack and sub enclosure that sits on the floor. The bottom of the sub enclosure will be fiberglass and the trim around the amps, subs, and other components will be fiberglass also.
Mapping out my design on 1/2" MDF. Amps will be in the back side-by-side. Front and center will be the two Eclipse 8" subs. To the right will be the Clarion processor and to the left will be a PPI FRX-456 crossover.
I used the router and perfect circle jig to get nice clean corners.
I used the router again for the inner edges.
Clamps and a straight board work wonders!
All the curves and lines finished. Tool longer than I expected though.
Next step was to cut them out. The jig saw was a breeze for this...just stay between the lines.
Once removed, I flipped it over and cleaned up the edges with a tracing bit.
And this will give you an idea of what it will look like when finished. Fiberglass will be stretched between the top and bottom pieces.
LOL, the router shoots dust everywhere! Just look at the wall. I know this looks like quick easy steps but it takes a very long time to line up cuts with the router. If you are off by as little as a 1/16" you'll have to do quite a bit of sanding to fix the error. I guess that's why the pros use CNC routers.
Up next, I have to duplicate the top piece on 1/4" MDF. After fiberglassing I will lay it over the top. That piece and the inner pieces will be painted. If I paint the fiberglass it will go blue/silver/blue. If I decide to vinyl the fiberglass portion it will go silver/black-vinyl/silver. I think both would look nice so I can't decide.
I've also got to create a few more baffles for the subs. It is going to sit up an addition 3/4" to 1.5" to accomodate for the stupid hump in the tire well.