My friend wanted a box built for his RF P1 10" 4ohm sub built into the passenger side of his trunk....and he wanted a tool box built into the sub box....so I built him one. I know I haven't seen anything like this before so I decide to put it up here for the world to see. The box is complete but I left it up to my friend to do the finish work on it since (as you can see from the pictures) he has gutted the whole jeep and is restoring/customizing it.
I cut all of the irregularly shaped pieces of wood and screwed them together one at a time. This was the first time that I had tried to bend wood and it would have been much better if I had used MDF for that piece but it was still usable and I wasn't worried about strength because I was going to add fiber glass to the back later.
I stretched and stapled a thick piece of fleece to fill in the missing piece. I used thick fleece because I had complete access to both sides of the fleece to apply resin. I then added 2 layers of unknown weight chop mat to the back of the fleece sloppily for me but it wasn't going to be seen.
I was patching some holes in the floor pan of the jeep with bondo-glass/resin mixture and used the leftovers on the inside of the box. The result was a box that felt like it was made of stone.
3 Weekends Later
I test fitted the box with the baffle installed.
Then I measured and traced the contours of the jeep to cut the rest of the pieces of the box. To do this I used a compass to trace the contours of the sheet metal to cardboard then used the cardboard templates to cut pieces out of plywood.
I left the square area of plywood in the opening of the tool box for strength and to be used as a work surface.
Using my jigsaw beveled at the angle of the seat belt I cut the curved line into the top of the box for the seat belt.
I chose the hinges because they are spring loaded so they will hold the lid open and closed. They are also very adjustable to accommodate for any small imperfections in the seams.
I marked where the box was on the sheet metal with a marker and then transferred those marks to the original trim panel. Then I used my Milwaukee cordless rotary tool with an abrasive cutting wheel to cut out the few parts that I could still use.
Temporarily installed until my friend is ready to finish it.
It doesn't take up that much room in his trunk.
The sub box is about .8~.9ft3 with about 1.5ft2 of 1" thick foam rubber.
I added the latch because the hinges weren't going to keep the lid from rattling.
You can see the other piece of OEM panel that still needs to be attached to the box and glassed.
I threw some jumper cables into the tool box to give you an idea of how much stuff you could store in it.
Some pics from the interior.
You can see how the amp fits perfectly in the space. Its only pushing 150W RMS.
The bars were riveted into the OEM carpet in the trunk and we decided they would make an awesome grill.
I am extremely happy with the way it came out. It is bolted into the floor with two 5/16" stainless bolts and one 3/8" galvanized bolt as well as to the side of the Jeep with two custom L brackets and screws which really increase the rigidity of the Jeep and Box.Dodge Magnum in progress:
Pioneer DEH-80PRS - PPI Amps - Dayton Subwoofer(s) - Exodus Anarchy's - Vifa Tweeters - Kinetik Battery