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hhr panel man 
Member - Posts: 5
Member spacespace
Joined: May 08, 2012
Location: Illinois, United States
Posted: May 08, 2012 at 8:32 AM / IP Logged  

Help/info for 1st fiberglass sub enclosures in Chevy HHR

I am gonna give making a pair of custom fiberglass sub boxes a try for my Chevy HHR Panel.

Initial thoughts with my audio/video install was to build some type of sub box amp rack Combo in the rear spare tire well.
But as my daily driver/semi show car that my HHR Panel is to me, I really did not like the idea of loosing the spare tire.
I have been using one Pioneer TS-W3002D4 12 In. Champion Series PRO subwoofer, in a Atrend E12Sv B Box Series 12-Inch Single Vented Subwoofer Enclosure, takes up Alot of room in the back area and hinders hauling stuff in general, and with my added rear seat in my Panel when the 60/40 split rear seat is folded down the sub box slides all over the place in back.

Sliding big sub box has gotta Go and I want Two of the Pioneer 12" subwoofers.

I found a Custom subwoofer install done in another HHR, contacted the owner and he had them custom made at SONUS Car Audio in Clarkesvile TN.

This is what I want to make/recreate.

fb/sb /ideas making these? -- posted image.

This is the area in my HHR Panel, the Flat area thats 20X12 is removable.

fb/sb /ideas making these? -- posted image.

fb/sb /ideas making these? -- posted image.

I'll be ordering up stuff from US Composites. What all should I get to make a pair of these? I have nothing but Time on my hands to give this project a try.

From the looks and from talking to the owner, looks to be a MDF backing and then a MDF Ring mounted off center then fleece stretched over it and resined, add some layers of fiberglass to the inside, and maybe a layer on the outside. and bondo it out smooth.
Originals were covered in black vinyl, and are 10" subs.

(I was a body and fender man for about 12 years full time a long time ago)

Pretty much same kinda design. I know my subs are 12" and I will need to expand the boxes for a little more depth I believe. To get the required •sealed box volume: 0.5-1.0 cubic feet •ported box volume: 0.8-1.6 cubic feet.
I Need / Want my floor space Open, and this type of install will allow that, plus let me use 2 subwoofers.
I just bought and recieved a second Pioneer GM-D8500M mono amp, and will be ordering up a second Pioneer TS-W3002D4 subwoofer and the matching Grill.
These were just done, and posted on a HHR Forum I am on and it's a perfect solution for me and to be able to have a pair of subs without sacrificing floor space or my spare tire, jack and other things I would like to carry in the well area.
As I said, I do have 12 years of body and fender, and auto painter experience, I have a complete woodworking shop in my garage, 6HP 80 Gallon air compressor, sandblasting cabinet, fully tooled to do just about anything, garage is Heated and is AC'ed as well.
I just never made a subwoofer enclosure before. Not saying it won't be hard to do, just that I can't afford to spend that kinda cash having them custon made.
I gutted the interior and sound deadend 90% of the interior roof to floor, doors are done with a layer on the inside outer door skin and then the door is sealed up and a layer on it directly behind the interior door panels, roof and floor are 100% covered, rear spare tire area is 100% covered as are the rear quarter panels.I did not tear the dash out to get in behind it and the firewall, to much work to do that. Huge improvement in the car overall. In the area were the door speakers are I did add a 12"X12" area with 3 layers (4 total overall) directly behind each of the speakers.
Ideas and thoughts on how to do this is what I am looking for, not sure how to achieve the outer rim area that fits around the outside edges.
Not sure how much materials I will need, 2 gallons of resin, sheet of 3/4" MDF, and how much and what kinds of fiberglass should I get?
Thanks

hhr panel man 
Member - Posts: 5
Member spacespace
Joined: May 08, 2012
Location: Illinois, United States
Posted: May 08, 2012 at 9:00 PM / IP Logged  

51 Views and no one has a clue?

Is there a fiberglass forum with active participants I can ask on?

awdeclipse 
Copper - Posts: 285
Copper spacespace
Joined: August 05, 2007
Location: Michigan, United States
Posted: May 09, 2012 at 9:47 AM / IP Logged  
Patience... Many viewers (including myself) most likely have no knowledge of the subject matter and simply view/browse for the sake of curiosity.
tommy... 
Gold - Posts: 1,901
Gold spacespace
Joined: December 10, 2004
Location: United States
Posted: May 09, 2012 at 3:02 PM / IP Logged  
hhr panel man wrote:

51 Views and no one has a clue?

Is there a fiberglass forum with active participants I can ask on?

This will be a commitment for the responder to continue with this long process... 51 views isn't many...But in the same breath... The Guys/Gals here... Are the BEST...Period! Patience Grasshopper... I know you want to get the ball rolling... There is SO much in this little box... AQnd when i type, i chicken peck... This post involves, at least, 75WPM. Took me an hour to type this... Geez
M.E.C.P & First-Class
Go slow and drink lots of water...Procrastinators' Unite...Tomorrow!
hhr panel man 
Member - Posts: 5
Member spacespace
Joined: May 08, 2012
Location: Illinois, United States
Posted: May 09, 2012 at 4:29 PM / IP Logged  

Your both right, and Yes I do want to get the ball rolling on this little project.

I am home all day, so I got nothing better to do than play with my little HHR Panel. I am 50 years old, not a kid.

fb/sb /ideas making these? -- posted image.

fb/sb /ideas making these? -- posted image.

I'll make one to get my subwoofer up out of the way first, completeing it fully, then make the second side.

Gotta have a Pair so both sides Match. fb/sb /ideas making these? -- posted image.

Bought so far for my little project-

Jasper #200 Circle Guide (Amazon)

Hit up Home Depot for these-

1LB. Box of SPAX Hardwood and MDF Screws #6 x 1.5 inches long(nice small heads)

2 SPAX T20 Driver Tips

2- 2'X4' 3/4" MDF

1- 2'X4' 1/2" MDF

-1 2"X4" 1/4" MDF

3- 1 Quart Multi Mix Containers

3 bags- 3M 8 sq.ft. fiberglass mat (i'll be buying more mat from USC when I place my 1 gallon resin order and other supplys)

1 bag- 3M 8 sq.ft. fiberglass cloth

4 Rolls of 2" 3M Blue Painters Tape

I'll be buying a gallon of resin and other supplies from USComposites.com, they no longer carry the B-440 Premium Polyester Layup Resin , should I just get the 435 instead? Is there a Replacement for the B-440?

I have routers, table saws, drill presses, large stand alone belt sander, jointers, drum sander, 14" disk sander, air compressor and a full assortment of air driven tools, fully tooled garage.

As a former Body & Fender man, the actual fiberglassin and bondo work is the easy part for me, looking mainly for suggestions on building the sub box itself, fabricating it. I just never built a custom formed sub box before.

I won't cut any corners to make these, I'll buy whatever I need that I don't already own.

Thanks

hhr panel man 
Member - Posts: 5
Member spacespace
Joined: May 08, 2012
Location: Illinois, United States
Posted: May 09, 2012 at 6:45 PM / IP Logged  

USComposites Order is looking like this so far. Any thoughts on it?

10 yards FG-10538 38" Width 1-1/2oz Chopped Strand Mat $2.55 a Yard = $25.50

1 Gallon SM-435100 - 435 Standard Polyester Layup Resin < size=2 face=Arial>< size=2 face=Arial>$ 30.50

SM-STY025 - Styrene Quart(32oz) $6.75

SM-MEKP080 - MEKP Hardener 8oz $5.50

SM-SWAX02 - Surfacing Wax 2oz Bottle $2.25

FR-1213A - Fiberglass Detail Roller 3/8" x 3" $6.70

$77.20 Plus Shipping

hhr panel man 
Member - Posts: 5
Member spacespace
Joined: May 08, 2012
Location: Illinois, United States
Posted: May 10, 2012 at 1:49 AM / IP Logged  

Pics of stuff I bought locally.

Would be nice to get some input here, I want to place my online order ASAP.

fb/sb /ideas making these? -- posted image.

fb/sb /ideas making these? -- posted image.


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