View Full Version : My first fiberglass project................

09-09-2006, 09:14 PM
So last night, i finally attempted working with fiberglass.

When i initially had my system installed, the shop hacked up my rear doors pretty badly to get my type-r's to fit. The speakers wouldn't fit under the door panel, in the factory speaker location, so rather than simpy removing the detatchable grille, they decided to cut a huge hole right smack dab in the middle of it.

My upcoming DIY comp. setup wont have any speakers in the rear, so a big nasty hole in my rear doors wasn't an option, so i set out to make some covers, and bring the doors back to a factory-ish appearance.

Here's a pic. of what my doors looked like with the type-r's installed.


You can see outlined in red, the area i decided to cover with my fiberglass, and also the hackjob speaker install, that not only destroyed the grilles in front of the factory speaker location, but also the panels next to it :furious:

So i got myself a gallon of resin, a bunch of woven fiberglass cloth, and went to town.

I did a LOT of reading on these forums about how to fiberglass, but after doing the first panel, i got more used to the process, and adapted the process to something that worked better for me, and ultimately gave me better results. I cut the cloth into larger squares than the "strips" most people use, and after each layer of mat was layed down and resined, i used a paint roller to press everything down.

On my first panel, i layed down each layer in 15 minute intervals, but the second panel i got much better (smoother) results that resulted in less sanding by laying down the entire 9 square foot pack, layer after layer, right in a row with no breaks, and then dumping an additional 2 oz. of resin on top of the panel afterwards, and rolling it evenly across the entire panel with the paint roller. Both panels turned out equally strong, but the one i did all at once required a lot less sanding afterwards.

Overall, it was a lot easier than i expected. I think all the reading and prep i did was just psyching me out, and it didn't come together in my mind until i actually got started, and then the process just flowed.

Also, i didn't find it necessary to use a fleece skeleton. I just used 3 layers of masking tape as my structure, and although a layer of masking tape is pretty much permanently a fixture on the back of the panel, the results were excellent, overall.

Here's a pic of a finished panel. This is post-sanding/pre-paint.



The finish will be rubberized spray-on bedliner on the face, painted to match the tan color on the panel, and then the piece will be epoxied to the door to be watertight, and then the entire back of the panel will be sprayed with 3 or 4 coats of spray on rubber undercoat/sound deadener. (it was already quiet, it's more for water-proofing, sound-deadening's just a bonus)

Let me know what you think!


09-09-2006, 09:18 PM
note: this is the rougher of the two panels, the other one's already outside being painted.

09-09-2006, 09:18 PM
what did u use to cut the door panel ??? a steak knife?

09-09-2006, 09:25 PM
hahaha, a dremel with an engraving attatchment, hahahaha

i cut the **** out of my finger, too

09-09-2006, 09:39 PM
need more pics!

Looks good so far.

09-10-2006, 10:29 AM
You gonna dress up the edge of that panel so it better matches the curve of the bottom edge of the door panel and you have a consistent border around it?

09-10-2006, 12:39 PM
You might wanna just wrap them instead of paint them, it will hide most of the imperfections.

09-11-2006, 11:52 AM
Not bad , but like helo said . Take your time , and clean up those edges . It will make the end results look so much better , and easier to achieve :)

09-11-2006, 02:56 PM
what did u use to cut the door panel ??? a steak knife?

lol. too funny.

09-11-2006, 05:44 PM
ya, i've been working on them little by little.

my biggest difficulty was simply making the forms, since i'd never done it before.

i've just been sanding them down, and trying to get the shapes perfect, i decided i'm not gonna paint or carpet them until i make my speaker pods for the front, so that i can see how those come out, and make all 4 match.

i actually had a really rough time trying to find a paint that would match my doors very well, so i may end up upholstering them with some sort of fabric.

i'm waiting to see how i end up doing the speaker pods, tho, to see if wrapping those in fabric will work, before i do anything to these.