fiberglass amp rack

install time>> don't ask! (about 2-3 days)

If I was not going to shows, I would not do this.  Its a lot of work, you have to take care of your trunk and the materials cost some money.  If I haven't discouraged you... then read on. 

This is for reference only, I am not liable if you screw your car up.  Use caution and common sense when working on your vehicle.  Read the directions (like you will) use the right tools and use the appropriate safety equipment.

Materials

> fiberglass resin & hardener
> fiberglass mat 
> fleece (t-shirt material) I used a 60/40 blend but other have advantages
> many disposable brushes sizes 1" to 3"
> high-build polyester primer
> sand paper (40, 80, 120 regular  180, 220 & 400 wet sand) 
> spray gun and air compressor
> disposable gloves
> "3M" Tape 1" and 2" 
> paper or plastic coverings
> Vaseline (this is not for your friend who is helping) 
> good ventilation area.  (will leave car undrivable while fiberglass cures)

Step 1 Determine the purpose and shape

This is the hardest part.  You must decide how much space you are willing to lose and what you want it to accomplish.  This is why I normally recommend that you take it to someone with experience.  I already had a functioning system.  Amplifiers where originally installed in the spare tire well.  But I wanted something more flashy.  Also my friend Jeff (He works for Concept Audio) wanted to use my car in his booth at dB Dragracing World Finals in Nashville TN.  I said ok but I really wanted to show off his stuff.  The fiberglass panel was designed to hold two 2002 amplifiers (950 watts each) and to display the subwoofers (through the face) without adding lots of weight.  Fiberglas is great for low weight.  

Step 2 Build the support

There's me hot gluing a temporary panel to my max for the face logo.  All the brackets made are just to hold parts of the fiberglass panel in place until it cures.  The finished install does not have these parts included.  

NOTE:  See how the car is taped and protected.  This is a very important part if you do not want fiberglass resin on the outside of your vehicle.  Basically, it will ruin the paint.  So please take care, cover more area than you think you will need and wear clothes that if they get ruined, you wont cry.  

Here is the area before the fleece is installed.  These brackets define the basic shape of the panel.  (For rookies, do not have your panel too far away from the edge of the rubber gasket.  If you do, it might not come out once it cures OOOOPPS) 

Step 3 Install the fleece

Stretching the fleece is the hardest part.  Take care to make it as smooth as possible.  All wrinkles must be filled in with a reinforced body filler like "Kitty Hair" or "Duraglas"  

The stretch fleece is tucked under your trunk gasket molding.  Coat the molding with Vaseline.  (nasty huh) this will prevent the resin from sticking to it. 

Follow the direction for adding hardener to the resin.  Then double the amount of hardener.  Make sure to wear those plastic gloves.  Resin does not easily come off skin.  It kinda wears off.  Use the disposable brushes and apply the resin to the fleece.  start in areas that is the farthest away and most difficult to cover.  (I am starting around the face in the back) This will help you get more done faster as well as prevent resin from getting on your skin and otherwise creating a big mess in your trunk.  Once you have covered the entire area.  let dry overnight.  If you pull it out as soon as it kicks (non completely cured)  you have a good chance that the shape will change and no longer fit (that means starting over)  Don't do that. 

That's all for now I need to find the rest of the pics.  More coming soon.