First Time with Fiberglass Santa Fe

Figured I would throw this up for the pro's opinions. It was my first time playing with FG. After 3 months of research and design, I finally jumped in and started a full redesign on my sub boxes. I've been taking most of the lessons learned here and on mp3car.com.

The ride is a 2004 Hyundai Santa Fe, not your typical show ride, but that's why I did it up, that and I got a fantastic deal on it as my wingman was the salesperson. Here is what I started with. The gaping hole was from the previous boxes I had made, the subs stuck too far back so they cut out some of the moulding. Not a big deal, they asked me prior to doing it anyway.

Did all the taping and layed down my first layer of glass. The first time, it was -10 degrees (I'm in Canada), and I didn't know that the glass wouldn't cure that cold. So the pics are actually from the second attempt. I only did 2 layers of glass to get the shape first.

[IMG]https://i15.photobucket.com/albums/a376/spawn12336/Fibreglass/Fibreglass009.jpg[/IMG]

I built the top and bottoms from MDF and attached them to the mould with shortstrand bondo glass. The original boxes had an issue with being sealed properly, so even though it's more work, I am taking extra steps to make sure that all seams are perfectly sealed.

On each side of the the cargo area are 2 little storage areas that are going to be used as the slot-b to the boxes tab-a. I filled them with expanding foam to stabilize them even more.

The floor and top were made with 1/2" MDF as they were going to be glassed over anyway, but the panel behind the seat is made of 3/4" mdf. Screwed, glued, and glassed in at the seams.

Again, I am working in an un-heated garage, so my best helpers are 2 small space heaters to help with the curing.

This was the structural base complete. It's 2 seperate sealed boxes, and a trim piece will be covering the join between the 2.

After 5 layers of glass on each piece, the speaker rings and support structure went in, with a test fit of the new subs. Most of the framing is either just for support of the rings and a few of the pieces that look randomly placed are there to give me place to staple the fabric down and shape the curves (freaking geometry)

Here the are fleeced and one side has resin, these pics suck as they were from my phone. I was supposed to be laying on 5 layers of glass today, but thanks to this freaking storm, I won't be driving 50 km out to the boondocks to work on it, until maybe later.

Before the questions get asked, The expected interior volume is 1.6 Cubic feet including the displacement of the speakers. The 6.5" speakers are isolated from the sub volume with FG compartments. What look like holes in the fleece are where it was stapled to the extra supports to shape the curves deeper, and will be filled and flattened out.

Looks frickin awesome. i miss my santafe

This is definitely the ichiest I have ever been. Saturday was the first sanding day. I smoothed down the irregularities, and made the flat parts nice and smooth. I also glassed in the chambers for the 6.5" speakers. All of the structural supports that were used during fleecing were removed as they aren't needed anymore for strength, the glass handles that now. Sunday was supposed to be the first layer of bondo, followed by the milkshake layer. I am now using Evercoat Plus 1 filler and shortstrand. According to Evercoat it is their replaccement for Rage Gold in Canada. This stuff blows Bondo out of the water in workability, and smells nowhere near as strong.

Here is what I left with tonight.

All the airspace I'll need for the new subs

inside the box behind the small chambers.

So much for Bondo Sunday. Freaking Daylight Savings Time, got there technically an hour late. Sanded off the excess of the small chambers and pulled out the plastic cups. Tried to mount one of the subs using the T-nuts, let's just say an hour wasted, T-nuts in the garbage. I realized that before I could bondo, I had to test fit everything again. So out with the current system, and in with the new. I also came to the conclusion that I needed to build the trim panel and do some taping before all of the bondo.

The Trim panel itself took over 2 hours of trial and error to get it right and finally finished, well the frame of it anyway, I still have to bondo it as well. I also fabbed up the shelf for the cap that will be in between the 2 boxes. So all in all, no bondo, but still alot of progress. Don't worry about the scratched to doodiee floor, it will have a new trim panel for itself soon.

You can see the outline of the special bits that are going to be added and wired up....

I should be at a few of the northeast NOPI shows in the states, and of course the Nationals in Atlanta. I was hoping to be ready for the ATCO show, but it's not looking promising.

And what in hades is VNB?

A few more shots from today's work (I have some time off)...

In my fight against gaps between the boxes, I tried an experiment, and succeeded. Went out and got some premium shortstrand filler by evercoat (this s*** is gold by the way! I love it!) and figured that 3 years of detailing and armour all would prevent it from sitcking to the panels. BINGO! I was right. So today was spent filling all of the gaps and a little shaping at the edge to flow smoother. It took 2 layers, but the pics speak for themselves.

MMMMMMMMM.... TIGHT!!

The only issue is that when you press the filler into the gap, it wants to fill ALL of the space, so it actually wraps around the panel making it slightly difficult to get out. A little carefull prying and "POP" she's out. You have to trim off the excess once it dries. Not a big deal.

This is how I left them tonight. Right up to the edge of the rubber strip on the door baby!

You've got some skills to build on,,,one small suggestion when you float your edges in, run a layer of masking tape where you're going to dynaglass your edges, it will still give you a tight fit but you won't have to clean your panels off everytime and it acts as a release agent.  Nice work though for a first build,,,

Thanks for the props guys. I went up to the edge to give me enough thickness that when I trim it back 1/4" it would still be strong enough to not have to worry about it cracking. Normally I would have run a line of masking tape, but all I had around was green painters tape, and with 3 years of detailing, it was sliding off faster than an egg on teflon. The excess came off with a little acetone and gentle rubbing.

Agreed on the PIA curves around the rings, that's the 5% unsanded on the one, waiting on the 3" DA sander to get here. and they are going to be painted. I colour matched parts of the interior last year to the exertior colour and will be keeping the blue and silver theme for the boxes and the liftgate. The colour is called moonlit blue. Looks darkblue almost black until the sun hits it.

This is what she looks like in the sun...

and on a cloudy day...

and the interior last season...

spawn12336 wrote:

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Hell yeah, it feels great. Here are 2 shots from last week when I was doing the filler, right after the filler was laid on and sitting for about 30 minutes. I couldn't get over just how shiny this stuff dries, is that normal?. I have sanded 95% of one of them down already. I should have them mostly finished next weekend. Hindsight tells me I should have tried to cheese grater the tight spots, but live and learn.

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(for people curious) That is the wax inside the filler coming up to the surface. Sand that off before continueing(sp?) on to the next step.

David mentioned a spray to help find the highs and lows, most body shops use graphite spray to find them, but a good alternative to it is charcoal powder. Grab a couple chunks of charcoal, throw it in an old sock, smack it with a hammer until it is powder, and pat that onto the surface. the charcoal will stay on the item and show you your high and low spots. Catch is, that these techniques (no offence david) are only really useful on larger flatter surfaces. The best way to really find smoothness is to close your eyes and lightly run your hand over the surface. You'll feel MOST irregularities that way, from there it is careful inspection at a low angle.

A quick update...

Did the final layers of bondo and sanding the last weekend in march, using the "milkshake method" (look it up). I am pleased with the turnout.

The boxes have been in since then and I have been breaking in the subs. Last weekend was my first chance to really turn them up, as for last season's measly 125.5 db score, let's just say it's a .... little louder now.  I ran through a few of my Bass Mekanik test cds, and was more than impressed with the sound now (if you have it, Bass Mekanik - Download, Track 16).

Went to the body shop to get a quote on painting them, so they should be in for paint the weekend after the move. I also met up with a decal contact out here as well in order to pick up a set for the trim panel that will be covering the split between the 2 boxes. Here's a teaser shot of the decals, all that is is a 4" led stripin behind the backing paper as the decals will be going on custom cut plates with frosted plexiglass...

It's been over a month and a half since the last update, but I was working on some other side projects and waiting my turn in the body shop.

Ah the fine art of the teaser pic....dusty as it is

Everything came out from paint yesterday, looks awesome, a few things to deal with, then pics will be up.

A little more work to do, but here it is installed...

Great job, spawn... however I do have one question... I looked up the "milkshake method" and didn't get any results. Mind filling me in please ^-^;

Thank you

Im assuming by the looks of the pics that the "milkshake method" is when you dilute the bog wiht fibreglass resin so its nice and easy to apply thin and sand off.

Great build up mate, youve done a great job and im lovin it

Sorry for the late reply, and thanks for the kudos lads. The milkshake is indeed the thinning of the bondo with resin to make it paintable as detailed in Velocity Motors' post How to make a fibreglass enclosureand in speakermaker's post fibreglass trick of the year

hehe ^-^; Thank you for the information...

Love the install

Arigatou!

This is what happens when I get inspired... Threw this together Saturday. It's been in the works for about a month now. I got tired of being razzed for the big stand that took like 10 minutes to set up. This stays in the ride... permanently... kind of ;) These are pics from the test fitting today. Anyway, pics....

Fleeced and glassed Yesterday. Trimming and sanding tonight, and maybe getting the filler layer on before bed. The milkshake will go on Wednesday, then final sanding. Thursday will be paint and clear hopefully, if not then it will be friday.

Pics... it is in 2 pieces now as the top is on drawer slides so that it extends out past the bumper.

that is a heck of a lot of money and time to spend on a Santa Fe, but i have to admit that craftsmanship is top-notch!

kudos to you for a GREAT install!   :-)

Sorry guys, I completed the project back in August and I clearly forgot to post any pics of it. And so to remedy that.... Completed pics (all taken from my cardomain as i can't access photobucket from work)!!

The finished stand. everything hides nicely behind the monitor.

then when I want to drop a few jaws, or just get bored at the shows and feel like djing.... the monitor gets lifted and out slides the controls. (not motorized, didn't see a need for it)

The completed touchscreen monitor replacing the centre console vents, the pc now runs on a dual monitor setup to make use of both monitors at the same time.

And this is why we do it....

The setup has won me 2 Best ICE trophies this year, which is really all I ever wanted. Thanks for the props guys, and the help along the way.

this are the best looking  trophies I have ever seen

Really....

I personally like the NOPI Chic's more...just me though. and yes, that's me

One word..................................................................R E S P E C T.

Eric