My Wagon build thread (Custom fiberglass box how to included!)

This is nothing compared to Seth1784's thread but thought I'd add this for us Wagon owners!

I didn't want to pay the premium for the JL Audio stealth box and since I've done a little fiber glassing here and there, I thought I'd give it another go! What I learned the first time was that adding fiberglass inside your car really stinks it up for weeks so I wanted to avoid that. I've heard some people use paper-mache as a pre-mold for the fiberglass, but it's not really sturdy enough.

I ended up getting Plaster Wrap, which can be found at any art supply store, it's plaster in a bandage for support. I also didn't want to cut my Subaru rubber mat so I molded my box around that. Here's a few pics of my process so far.

I used duct tape to mask off where I was going to plaster wrap. I didn't add any mold release though I should have. You can use caranuba wax as a mold release agent.

http://jay-d.com/brooklyn/subbox/subbox-01.jpg

First layer of plaster wrap. It's very easy to work with. I used a spray bottle and paint brush (dipping it in water) to apply. Spray the duct tape first, add the bandage in little pieces, use the paint brush to paint on.

http://jay-d.com/brooklyn/subbox/subbox-02.jpg

Waiting for it to dry.

http://jay-d.com/brooklyn/subbox/subbox-03.jpg

It wasn't too difficult to take it out. Used a scraper to separate it from the duct tape and slowly pulled it out.

http://jay-d.com/brooklyn/subbox/subbox-04.jpg

http://jay-d.com/brooklyn/subbox/subbox-05.jpg

http://jay-d.com/brooklyn/subbox/subbox-06.jpg

http://jay-d.com/brooklyn/subbox/subbox-07.jpg

I'll update with more pictures as I progress!

Looks like a fun project to fabricate up.

Though I'd be hesitant to use duct tape (seeing as you didn't use any mold release). Painter's tape probably would have been my choice.

And hopefully that plaster wrap cleans off easy, seems you went higher than you envisioned.

Though there is also Wicked CAS' magic box available, but you'd still need to trim the mat which you don't want to do.

It definitely is!

I tried using painter's tape, the green one, but it would not stick to the mat which is why i went for the duct tape!

The plaster wrap is water based, so all you need is a damp cloth and it rubs off really easily.

In my previous legacy, I added the fiber glass in the car and I got some resin on the carpet.. totally ruined it! I didn't want that again, so I was careful when looking for a product and plaster wrap is the best of both worlds! They use it to make masks for kids, non-toxic and water based.