How much material to use?

Hey man, you are right about the drum. If you are just going to do the corner of you trunk, I sugest you go to a marina or any other place where the sell boat repair supplies. If you go there, there have cloth AND mat on large rolls and it cheap!! I'd say get about 4-5 yards of the chop mat and 1 yard of the cloth for finnishing purposes (it should all come out to be under $20 for the 'glass). And if you haven't started the project yet, get a 3/4in. sheet of MDF for the bottom of the box and the ring to hold the sub. And the you can use the extra wood to support the ring. I don't know what kind of sub you are planing on, or how much power you will be pushing, but i ALWAYS use a minimum of 4 layers for strength. Thats just my opinion, other people will tell you more or less but in the end it comes down you your own preference. And as for the resin, that will run at least $25-$30 a gallon. You should get at least one, and before you do the project try something small. it will teach you how to mix the resin/hardener, and will give you a feel for 'glassing. Post pics through out you project, we want to see. Best of luck to you and i Hope i was able to help.

PS,

   I don't think you should use a t-shirt. Go to wal-mart and by a yard of fleece, under $5, and it will absorbe the resin much better the a t-shirt would. GOOD LUCK!

What I ment was the biggest can wal-mart sold (1 gallon) I didn't think you were going to the surplus store.3 packs of 8 sq. foot matting.  Old t shirts are usally free out of a closet and work very well swet shirts do to. Or go buy some fleece head liner silk your moms pantys what ever its only the base. Anyhow sorry for tryin to help.

For that project you're going to need the following materials:

- 3M 2" masking tape

I use the 1.5 ounce chop mat that comes on a 4" wide roll. It speeds up the time to cover the area. For an enclosure like that you should be fine with four layers of 1.5 ounce mat. Three layers if you go with 2 ounce. I get that and good quality resin at US Composites.

Tape off the area, mark your cut line, spray it with Super 77 and lay up the first fiberglass layer. Mix up your resin and soak it all the way through to the tape. Once the first layer is finished lay up the next layer and so on. Don't mix the resin too hot or it'll try to warp on you as it cures. Let it cure in the vehicle.

Once cured, remove the fiberglass shell and peel off the tape. Set it in the sun for some more curing. Then cut out the shell and sand it to fit. Put the shell back into the trunk and secure your woofer mount where you want it.

Pull the piece back out and wrap the shell and frame with fleece. Resin this and let it cure. Sand it down and use body filler where needed. Let the filler cure and sand it again. Cut out the woofer mounting hole and your speaker terminal cup. Blow out or ShopVac the enclosure to get out the major debris.

Carpet the enclosure and wire it up. Mount the woofer and grill to finish it off.

When you're done it should look something like this:

Good luck!