Thread: Show Me Your Box!
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Old Nov 17, 2010 | 01:20 PM
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F117NH
Joined: Jan 2009
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Default Re: Show Me Your Box!
Ok everyone, I will now try to explain how i built this thing. please hang with me as i may forget a few things, and there for i will be putting this into parts, so if anyone has questions they can simply say what part they are referring to, or just quote if its a small bit.

Day 1
Part 1:

Starting with a stock trunk, i measured the depth, width, and the height i wanted the box to come up to. The first problem was that the subs needed .60CF (not the .75 i was calculating earlier) so I had a depth and width that could not move out more the 35"w and 23"D, so that meant that the height would need to come up to meet the needed Cubic Footage. so i found that a high of 5 inches would make the INSIDE dimensions correct.

Next cut the wood...

Part 2:

I talked with a local auto sound place, (that i trust) Nevada Auto Sound, (btw any one in the Reno, Sparks area, if you need anything mobile audio then they are the guys to go to!) and asked them a ton of question about the wood they like and why. with there recommendations i went with a 5/8 inch MDF. now as far as the question of why the 5/8 over th3/4 ill get to that in a bit... But now that i was thinking of wood i realised that i did not figure in the witdh of the wood in making my desgin of the box... i would then have to cut the width and depth to fit the wood and still have the correct CF on the inside. so up goes the height... there for the pick of 5/8 over 3/4, remember i want to have as much storage space in my trunk as i can fit... so height is everything! so although the 3/4 is better i was assured that the 5/8 would be fine. and it has been!

So I had this grand plan of cutting all the wood my self and just when i was about to pull this sheet of 5/8 of the rack a Home Depot assistant says he can help me get the wood done and as i was telling him about the build i realized that he can cut the wood on the wall saw... i had him cut it all! SAVES SO MUCH TIME!



Part 3:

Assembly started with fitting the base to make sure it fits... now to be sure i didn't have Home Depot cut the wood to small i had they cut it over sized by about 3 inches, this said i had a bit of cutting. i cut the base to size and made sure i had the space for the walls to fit on the oust die of the base. again assuring the height to be as low as possible.

With wood glue and self tapping screws i put the walls up with a bit of help from a friend standing on the base as i screwed in the walls. Its not pretty and does not have to be.





With the walls dry it was time to seal them, i used a white to clear silicone, i don't remember the exact brand but any silicone will do...



after that it was later and time to stop.

Day 2
Part 4:

Cutting the holes for the subs was not hard. Each sub came new in box and with them was an instructions sheet with a hole cutting template. most if not all new subs will come with this. next was too find out where i wanted the hole in my box, i had two options, mount them toward the back , or to the front, well i wanted to port the box. So the port would to have a places to draw and push air but not directly to the sub. it had to be on the bottom and the sub on the top, forward part of the box. so i messured a center line and a distiance for each side, left, top, and, right that was the same so it would look centered. I cut and mounted the template onto the wood. i them used a good ballpoint pen to trace the template and make my marks for cutting. Next was to cut the hole, with a 5/8 drill and my hand held jigsaw i slowly cut out the mounting holes!



Part 5:

Now that i knew where the ports were going it was easy to cut the port holes using a 3 1/2" hole saw, and then mounting them. i used wood glue to hold the pipe to the outside wall and then found a few scraps to hold up the end of the pipe that was in the box. the pipe is a black plumbing pipe (i have no idea what its really called...) 3 inch inside diameter, 3 1/2 inch outside diameter. Its perfect for porting because its not heavy, but it has a 1/4 think wall so its not going to fail under heavy vibrations.
 
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