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The Showroom
This is the place to show off your BMW to other members of the community. Post pictures and videos of your car and the modifications you have done to it. If you need a picture of something on a coupe, sedan, convertible or touring you will probably find it here!

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Old 08-04-2006, 11:14 AM   #1
LAFENGAS
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Arrow DIY PROJECT: Sub Enclosure made from Scraps *pics*

Alright, my mission:

1.) To build a sub enclusre entirely from scrap material i have laying around
2.) Make the enclosure as strong and lightweight as possible
3.) Maintain 100% of my trunk space
4.) Bring mission statements #1, #2, and #3, together to be a good looking, quality product.


The engineered side of it (not exactly an engineering marvel, but the things that needed to be considered):

1.) Design an enclosure that can be kept as light as possible, strong as possible, and meet the exact volume requirement as set forth by the manufacturer
2.) Design the enclosure to keep the system's Center of gravity as low as possible within the car
3.) Use quality materials with great acoustic properties


Materials used: (All scrap laying around)

1.) Carbon fiber -great strength and formability
2.) Ballistics kevlar -great material for acoustics, strength
3.) Fiberglass - ugh, i hate fiberglass but used it to seal the base of the enclosure
4.) MDF board for the decoy speakers
5.) Ultrasuede
6.) Headliner Foam (from my seat project)
6.) Bullet Proof Glass - because i can.



I didn't take many pictures of the process, but the main cylinder was formed around a concrete forming tube, 24" is diameter. The main body is formed with 2 layers of Carbon Fiber sandwiching 2 layers of Kevlar.

Once the cylinder was formed, I placed it in the trunk and layed more kevlar with a fiberglass top layer to make sure it forms to the bottom of my tire well. During the epoxy curing process, I place 3 double lined trash bags filled with water to keep constant pressure.

with all that said, plus some cutting, this is what you get:



The subwoofers i purchased weren't delivered yet, so i made some decoy speakers up to the exact size so I could posistion them to fit into the enclosure and make sure I had clearance where i needed it:



the decoy speakers in place and braced with some scrap alumium to hold their posistion:


Then using my old trunk floor from my previous sub enclosure set up, i strectched some fabric across the opening and formed the top piece of the enclosure



Once this piece had fully hardened, i layered a bunch of random carbon fiber scraps i had from previous projects to the backside for reinforcement.



molded all 3 pieces together (the floor, the enclosure face, and the cylindrical bottom) and smoothd everything out.



Covered everything with a headliner foam to help with the overall look and feel once the aesthetic layer is added. It smooths out all the minor imperfections too:



Finally, covered the floor with black suede to match my seats:



Using some of bullet proof glass scrap (it's hard to see, clear) I had from some old robot projects, i engraved my logo. The final install thread will show this piece in place. Notice the bullet hole and bullet embedded in the glass... i tested it.




and that's it, now i have an ICE that utilized nothing but scraps. Will post pics once everything else around the enclosure is completed and installed.

Final Specs:

Weight: Enclosure: 8lbs
Floor: 4lbs
Speakers: 25lbs
Speakers:
2-JL 10w3v3's
Amp:
JL 500W/1




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Old 08-04-2006, 11:16 AM   #2
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ur insane
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Old 08-04-2006, 11:23 AM   #3
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"bullet proof glass - because i can"

another fantastic DIY...
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Old 08-04-2006, 11:31 AM   #4
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Quote:
Originally Posted by LAFENGAS
6.) Bullet Proof Glass - because i can.
that just made my day but seriously, those "scraps" def came out nice and you are rediculous.
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Old 08-04-2006, 11:33 AM   #5
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awesome job for just scraps
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Old 08-04-2006, 12:30 PM   #6
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damn nice setup.. where will the amp go, under the back deck?
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Old 08-04-2006, 12:30 PM   #7
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you are amaZING my friend...

are those the W3v3's?

have u hooked them up yet? how do they sound?
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Old 08-04-2006, 12:32 PM   #8
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Quote:
Originally Posted by budman
damn nice setup.. where will the amp go, under the back deck?
I'll update everything as it's completed....but essentially, yes.
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Old 08-04-2006, 12:47 PM   #9
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nice job!
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Old 08-04-2006, 01:14 PM   #10
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that looks superb! now make one for me
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Old 08-04-2006, 01:22 PM   #11
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you're my hero
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Old 08-04-2006, 01:22 PM   #12
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that's awesome man
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Old 08-04-2006, 01:28 PM   #13
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Very nice.........very cool setup. I definitely want to see the end result.
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Old 08-04-2006, 01:30 PM   #14
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Any tips for laying down the ultrasuede?
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Old 08-04-2006, 03:28 PM   #15
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Quote:
Originally Posted by hookem12387
Any tips for laying down the ultrasuede?

- 3M Super77
- light coats of the adhesive on both the fabric and substrate
- start at one side, work to the other
- stretch and pull as needed.

voila!!
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Old 08-04-2006, 03:37 PM   #16
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wow, that looks awesome..... u r the DIY king.....
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Old 08-04-2006, 03:41 PM   #17
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nice job. that black suede looks sick.
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Old 08-04-2006, 03:56 PM   #18
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dam man i hope your doing this stuff for a living cuz u got skills bro
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Old 08-04-2006, 04:13 PM   #19
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end result looks awesome LAFENGAS definitely want to see it after the bulletproof glass goes up.
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Old 08-04-2006, 04:22 PM   #20
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freaking dope that looks awsome
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