 This cool custom spare tire...  This cool custom spare tire well speaker enclosure will help the 10-inch Sony XS-L1035 Xplod subwoofers deliver maximum bass at a minimum price. |
 Begin by removing the trunk...  Begin by removing the trunk carpet, spare tire and jack. Even though the tire well is off-center to allow clearance for the muffler and exhaust tip, the speakers will be centered in the trunk. |
 No special tools are required,...  No special tools are required, but you'll need a sabre saw, electric drill, the supplies shown here and a can of Touch 'n Foam expanding sealant. |
 After Jamie determined the...  After Jamie determined the size of the box, he began by cutting two cardboard templates in the shape of the well and the top of the box. |
 Trace the templates' outlines...  Trace the templates' outlines onto the 3/4-inch MDF (medium density fiberboard). |
 Cut out the MDF using an electric...  Cut out the MDF using an electric sabre saw with a wood cutting blade. |
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 Then set the front and rear...  Then set the front and rear peieces of the box in the well, trim as needed to fit and measure the top to make sure that it is level with the trunk lip. |
 Cut two more pieces of MDF...  Cut two more pieces of MDF to form the frame of the box and check the fit. |
 Take the frame pieces out...  Take the frame pieces out of the trunk and apply Titebond II wood glue to the ends of the side pieces. |
 Using a 5/16-inch bit, drill...  Using a 5/16-inch bit, drill into the outer ends of the large pieces to countersink the screw heads, drill pilot holes with a 1/32-inch bit and screw the frame together with 1 1/2-inch long wood screws. |
 When the glue has dried, set...  When the glue has dried, set the frame back in the tire well. |
 Attach the box frame to the...  Attach the box frame to the floor of the trunk at several places using small L-shaped brackets. |
 Wearing vinyl gloves, apply...  Wearing vinyl gloves, apply a generous amount of Touch 'n Foam all of the way around the bottom edges of the box to completely seal it. Let it expand and cure for 24 hours. |
 Here's how the foam looks...  Here's how the foam looks once it's expanded and hardened. |
 Next, cut a piece of MDF for...  Next, cut a piece of MDF for the top of the enclosure and make the countersunk screw holes. Note how Jamie has drawn out the area where the speakers will go based on the center of the trunk, not the center of the enclosure. If you wanted to stop here, you could glue and screw the lid in place, make cutouts for your speakers, cover the box with material and you'd have a good sealed enclosure. We'll continue however. |
 With the lid out of the car,...  With the lid out of the car, drill a pilot hole and cut out the inside area of the lid. |
 Using the cardboard template...  Using the cardboard template that comes with the speakers, draw out six mounting rings on the MDF. |
 Drill a pilot hole and carefully...  Drill a pilot hole and carefully cut out the inside of the mounting rings. |
 Then carefully cut out the...  Then carefully cut out the outer edge of the mounting rings. |
 Place the lid back on the...  Place the lid back on the enclosure and determine the positions for three lower mounting rings and mounting tabs. |
 Remove the lid, flip it over...  Remove the lid, flip it over and attach the three lower rings and mounting straps to the lid with 1/2-inch wood screws. |
 Jamie shows us how the lid...  Jamie shows us how the lid and lower mounting rings look at this point. |
 This shot shows the lid in...  This shot shows the lid in place with the upper speaker mounting rings also. |
 The mounting rings are also...  The mounting rings are also attached to each other with mounting straps to make sure that they don't move. |
 Next, staple the black speaker...  Next, staple the black speaker cloth over the top side of the lid. |
 Drill countersunk mounting...  Drill countersunk mounting holes in the upper mounting rings. |
 With the upper mounting rings...  With the upper mounting rings over the cloth, attach them to the lower rings with 1 1/2-inch wood screws and "sandwich." |
 Wearing gloves, mix a small...  Wearing gloves, mix a small amount of fiberglass resin with hardener and brush it on generously to saturate the cloth, covering everything but the area inside of the rings. |
 Continue applying resin until...  Continue applying resin until the cloth is covered as shown. |
 While the resin is still wet,...  While the resin is still wet, apply the first layer of fiberglass mat in small sections over the cloth and trim to fit. |
 Cover the entire area as shown...  Cover the entire area as shown with fiberglass mat. |
 Make "relief" cuts in the...  Make "relief" cuts in the mat at the corners so that it will lay flat. |
 Mix more resin ("hot" so it...  Mix more resin ("hot" so it will dry quicker) and, using smooth even strokes from the center of the edges, brush it on thick to completely saturate the mat, making sure that glass fibers don't lift or stick up. |
 Set the lid in a warm, well-ventilated...  Set the lid in a warm, well-ventilated place to dry. |
 Flip the lid over, repeat...  Flip the lid over, repeat mat and resin steps on the underside, and let it dry thoroughly. |
 Using 100-grit sandpaper,...  Using 100-grit sandpaper, sand down any high spots and rough edges on the topside of the lid. |
 The surface is now ready to...  The surface is now ready to have a coat of resin/body filler applied. |
 Mix resin with body filler...  Mix resin with body filler (the consistency of thin toothpaste) and brush it on the topside one area at a time until you've covered the entire surface. |
 Set the lid in a well-ventilated...  Set the lid in a well-ventilated area and let the filler harden enough to sand. |
 Cut the cloth out inside the...  Cut the cloth out inside the mounting rings. |
 Sand the entire surface to...  Sand the entire surface to remove any high spots. |
 Remove any body filler or...  Remove any body filler or mat inside the speaker mounting rings with a half-round file. |
 Mix body filler with cream...  Mix body filler with cream hardener, apply a thick even coat to the entire surface with a plastic paddle and let it dry enough to sand. |
 Using 36-grit sandpaper, smooth...  Using 36-grit sandpaper, smooth and shape the surface, let it dry thoroughly and finish sand with 300- to 600-grit. |
 Attach the lid to the box...  Attach the lid to the box with 1 1/2-inch wood screws and it's ready for the final filler coat and paint at the body shop. Note that even though the box is off-center, the speakers are in the center of the trunk. The air tank and other components will be positioned to the right of the box. |