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1: Build a frame work for the enclosure. The bottom and front panels
of the enclosure are built using MDF. Save the cutouts of the front frame
work for later in the build. |
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| Step
2: Once the frame work is sized up, remove and use the front frame
to trace the front baffle. Make sure to trace the inside as well as the
outside. |
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3: Assemble the frame work. Notice that the cut out brace allows
air flow while increasing the stiffness in the center of the enclosure.
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4: TacMat, placed behind the frame work, is used as the enclosure
back wall. TacMat cushions and insulates the fiberglass from the vehicle,
forming a non-resonant composite enclosure. This stops the squeaking noises
common with fiberglass/metal contact. Once the TacMat is positioned, use
a marker to trace the edges of the frame work. |
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5: Working outside the vehicle, hot glue the TacMat to the
frame. Trim to fit. Once completed, reinstall in the vehicle. |
  
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6: Tape off and protect the area to fiberglass. TacMat does not
require taping off the area behind. This is a great time saver. Notice how
the TacMat is pulled above the frame. This will be trimmed off after the
fiberglass is set. |
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| Step
7: Fiberglass the enclosure. Make sure to pay special attention
to sealing the front framework to the fiberglass and TacMat. The quality
of the bond will determine the quality of the enclosure. For best results,
use multiple small strips of fiberglass cloth. Build up the enclosure so
that the fiberglass is approximately ¼” thick. Trim off the
excess TacMat around the vehicle. |
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8: Once the fiberglass is completely cured, remove the enclosure
from the vehicle. For best results, wait 24 hours to remove the enclosure.
This will ensure that the shape remains intact. |
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9: Next apply DynaSpray (Dynamat’s liquid damping material) to
the inside of the enclosure. This will further damp the fiberglass enclosure.
The combination of TacMat and DynaSpray transforms the fiberglass into
a non-resonant enclosure. |
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| Step
10 Notches were placed in the front of the enclosure to clear
mounting tabs for the factory panel. These holes are sealed with Kitty
Hair (fiberglass strands suspended in body filler). Follow instructions
on the product for best results. |
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| Step
11: Taking the cut-outs from the front framework, adhere Dynamat
Original by applying adhesive to the logo side of the product and
the panels.
For best results, use and upholstery grade adhesive. If you do not have
access to that, you can substitute 3M Super 77. |
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Step 12: Remove the Dynamat Original
release liner and apply to the front baffle. Use the guides you traced
in Step 2 for alignment. The
benefit of the double thick baffle with Dynamat Original is two fold.
The thicker baffle provides an extra sturdy mounting for the woofer.
By sandwiching Dynamat Original between the two MDF panels, the result
is an internally damped front baffle that is extremely dead. Rapping
on it with your knuckles sounds like concrete!
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| Here’s
the enclosure with the so far. |
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Step
13: Tile DynaXorbs on the back wall of the enclosure. DynaXorbs
are designed to absorb the back-wave noise and distortion of the subwoofer.
The results are reduced internal enclosure reflections which enhance the
sound quality of the subwoofer. |
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| Step
14: Apply masking tape to the backside of the woofer mounting
hole. This is a simply way to ensure that adhesive sprayed to the exterior
of
the enclosure does not get inside the enclosure. When mounting the front
baffle to the enclosure, nails work fine but screws are preferred.
Screws ensure a tight bond between the front baffle and enclosure. |
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15: Cover the enclosure. Use your desired finish for your
enclosure. I chose a simple trunk liner because my enclosure is hidden
behind the factory
side panel. |
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Using this
construction method, I was able to construct a 1 cubic foot enclosure
that hides behind the factory side panel. Resonances typical in fiberglass
construction are non-existent. The enclosure is roughly half when weight
as a comparable MDF enclosure. Not to mention that a enclosure this size
would not have fit behind the factory panel.
This woofer
is definitely heard but not seen. The JL Audio 8W7 (yes an 8 inch)
is
able to achieve a respectable 129dB when tuned for sound quality. With
great low-frequency extension, the sound is effortless and the performance
is much larger that the 8 inch woofer |
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