molding interior parts, will it work?

I am going to make speaker pods for my Honda civic(1999). I am wanting to make the whole thing out of fiberglass but im wondering if that is possible now because of some of the special parts that make the door fit exactly with the dash on the very side. 

The first picture shows the door and how it looks right now; it will look 100% clean when i start tho, i just have some junk on the door.

I see that the problem I have is the clearance of the door against the dash and the molding that it has with the kick pannel.  What I am thinking of is using plaster of paris to make a negative mold of that door piece arund those areas...then when that is made and hardened, i will take fiberglass/resin to make the positive mold of the structure. after i have made that positive mold, i would be able to cut apart parts of the door piece that i will need to fit the fiberglass door pod correctly.

Does this sound like it will work?

Here are pictures to show what im talking about: the first picture is the door itself and the 2nd showing whats against the side of the dash

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What you can do to make sure that you get the clearance from the door to the dash is to use 1/4" foam ( or more ) attached to the side of the dash and then when fiberglassing the door close the door over the 1/4" foam ( that you will ahve covered with tin foil ) and this will give you a 1/4" space to work with that will be contoured to the shape of the door.Jeff

Velocity Custom Home Theater

Mobile Audio/Video Specialist

Morden, Manitoba CANADA

Velocity Motors wrote: What you can do to make sure that you get the clearance from the door to the dash is to use 1/4" foam ( or more ) attached to the side of the dash and then when fiberglassing the door close the door over the 1/4" foam ( that you will ahve covered with tin foil ) and this will give you a 1/4" space to work with that will be contoured to the shape of the door.

alright ill see if i can do that...wouldnt it be hard to fiberglass it when its on the door tho?

I always fiberglass on the door especially when it comes to fitment parts of the door. This way your not going to have any guess work when it comes to closing the door & asking yourself " will thie door close properly ? "Jeff

Velocity Custom Home Theater

Mobile Audio/Video Specialist

Morden, Manitoba CANADA

Velocity Motors wrote: I always fiberglass on the door especially when it comes to fitment parts of the door. This way your not going to have any guess work when it comes to closing the door & asking yourself " will thie door close properly ? "

how do you account for the  vinyl? do u add extra tap along the edges where the vinyl will wrap around?

what im thinking of doing now is making a  mold like this below, pull ir off of the door, trim it  so it looks like the picture below...

then I will attach that trimmed piece to the door and do the fiberglass from there, correct?

After this is attached, i start puttign the speaker ring, fleece and some glass on this part while its on the car door

Velocity Motors wrote: I always fiberglass on the door especially when it comes to fitment parts of the door. This way your not going to have any guess work when it comes to closing the door & asking yourself " will thie door close properly ? "

how do you account for the  vinyl? do u add extra tap along the edges where the vinyl will wrap around?

what im thinking of doing now is making a  mold like this below, pull ir off of the door, trim it  so it looks like the picture below...

then I will attach that trimmed piece to the door and do the fiberglass from there, correct?

After this is attached, i start puttign the speaker ring, fleece and some glass on this part while its on the car door