View Full Version : sealed fiberglass doors

06-27-2007, 11:27 PM
i'm gonna be glassing my doors. i'm gonna glass the entire area on the bottom(outlined in red) its going to house a 7" and a 1" tweet. i can glass the front...easy enough mount my rings then wrap and glass. but how would i go about sealing it on the back side. i'm probably gonna end up cutting the panel in half, mounting the top half w/ the clips and screws. so would the best way be to wrap the front, and glass it...then cut the plastic out of the back and get a piece of wood for the back and glass it together? heres pics of what i'm working w/. any help GREATLY appreciated.
http://img176.imageshack.us/img176/9991/1016590hb1.jpg (http://imageshack.us)
http://img167.imageshack.us/img167/1491/10165902pf5.jpg (http://imageshack.us)
http://img329.imageshack.us/img329/3357/1016593rs5.jpg (http://imageshack.us)

06-28-2007, 07:53 PM
ok, so i started the driver side today. i got the panel off, and cut. now that i have it apart and see what i'm working w/ i think i know what i'm gonna do. there is alot more room inside the panel than i thought. first i'm gonna glass the back, from the front, and build it up the sides. then place the rings, and wrap it.

http://img256.imageshack.us/img256/8086/1016598ce1.jpg (http://imageshack.us)
http://img256.imageshack.us/img256/1912/1016594ji8.jpg (http://imageshack.us)

this is a crappy pic, but you can see the depth of the panel...
http://img256.imageshack.us/img256/1526/1016596fq1.jpg (http://imageshack.us)

06-29-2007, 05:51 PM
first...i had to rivit this little guy on. my soundstage was awfully lop-sided...
http://img407.imageshack.us/img407/4435/1016609rl2.jpg (http://imageshack.us)
here it is w/ fabric sealing the backside, then resin....i just needed something to work on. tommorw(hopefully) it'll get some glass.
http://img525.imageshack.us/img525/1512/1016607by5.jpg (http://imageshack.us)
http://img407.imageshack.us/img407/192/1016608wi1.jpg (http://imageshack.us)

06-30-2007, 01:15 AM
I'll be watching to see how yours turns out as I'm getting ready to do something very similar.

Still haven't decided 100% how I want to do it, but am considering doing the entire lower panel like you are.

Keep posting pics/updates, so I can get some ideas...

06-30-2007, 07:57 AM
i just ordered some seas neo tweets :) http://www.madisound.com/catalog/product_info.php?products_id=1734&osCsid=d9bf4608815b0ad11c08b050b9b65a07
and if i get the mids i want, i will be running 7" scanspeaks :)
where in ill you at?

06-30-2007, 01:16 PM
http://img339.imageshack.us/img339/4248/1016610bg9.jpg (http://imageshack.us)

07-01-2007, 12:55 AM
more pics...
http://img227.imageshack.us/img227/7443/1016611zz6.jpg (http://imageshack.us)

this is where it sat the first time...i didn't like it, so i re did it. moved it in a little, sorry no pics of the second :(
http://img187.imageshack.us/img187/9518/1016613vc4.jpg (http://imageshack.us)

work space in my garage...
http://img184.imageshack.us/img184/9350/1016614et3.jpg (http://imageshack.us)

wrapped and ready to go
http://img187.imageshack.us/img187/3277/1016615vn1.jpg (http://imageshack.us)

resined up ;) i screwed w/ it too much (as usual) the glue let go on the 7" ring, so i got the pliers holding the material down till the resin cures...
http://img187.imageshack.us/img187/1893/1016616nk5.jpg (http://imageshack.us)

07-01-2007, 10:27 AM
Excuse my nosyness, but why do you have so many stoves? :laugh:

07-01-2007, 10:34 AM
They are washers and dryers. But I to wonder this.

Otherwise, nice build. Are you sure that the panel that you are glassing on will fit back on the door?

07-01-2007, 10:36 AM
Excuse my nosyness, but why do you have so many stoves? :laugh::laugh:

07-01-2007, 10:37 AM
Excuse my nosyness, but why do you have so many stoves? :laugh:

Those are not stoves :wow:

07-01-2007, 10:58 AM
well lets just say i don't have much luck w/ washers or dryers :( but there is one stove in there...its not in the pics, but theres one there.

07-01-2007, 11:01 AM
i just ordered some seas neo tweets :) http://www.madisound.com/catalog/product_info.php?products_id=1734&osCsid=d9bf4608815b0ad11c08b050b9b65a07
and if i get the mids i want, i will be running 7" scanspeaks :)
where in ill you at?

Nice choice on speakers. I'm currently running the Vifa XT25's and just made angled rings to get them on-axis, MUCH better. But I still might try the Seas large format alum tweets.

I'm up near Gurnee/Six Flags area...

07-01-2007, 11:22 AM
why would the panel not fit? i glassed it on the floor so it was flat. i'm suprised that noone noticed what i used to hold the rings in place...:laugh:

07-01-2007, 11:58 AM
i noticed pencils.

i like chopsticks myself.

and nice to see you back here again. i have not seen you around in ages.

07-01-2007, 12:49 PM
Should turn out well.


07-01-2007, 12:55 PM
test fit :)

:) I LIKE :)

http://img84.imageshack.us/img84/9545/1016621iq3.jpg (http://imageshack.us)
http://img110.imageshack.us/img110/8057/1016622id3.jpg (http://imageshack.us)

07-01-2007, 01:06 PM
Why do you have pink heat/AC control knobs?


07-01-2007, 01:11 PM
Why do you have pink heat/AC control knobs?


funny you should ask. they weren't supposed to turn out pink :suicide:
i pulled the rubber off the front of the knobs so they would be red, and the whole knob would light up red, you know, the pontiac's have ALL red dash lights. well.....ya, it *****, i cant put the rubber back on.

07-01-2007, 01:33 PM


07-01-2007, 05:18 PM
skills on the pink....

and i'm suscribed, excited to see how this ill turn out

07-02-2007, 05:59 PM
threw some speakers in to get an idea of the sound, and since i won't be able to work on it again till i get the bosses kids' box done. sounds nice really brings the midbass alive.
http://img248.imageshack.us/img248/4863/1016625jo8.jpg (http://imageshack.us)

07-02-2007, 06:29 PM
nice so far keep us posted

07-02-2007, 09:22 PM
Once I see finished pics I'll be motivated to do mine. Coming along nicely.

I'll be doing 2 mids, side by side, and angled back/up, any tips on how to stretch the fleece over them?

07-02-2007, 10:38 PM
little info i learned researching my project. i'm doing my for sq though...
if your set on doing 2 mids(playing the same freq) you need to have them on the same plane and the same distance from your ear, or else you'll end up w/ tons of cancellation. if you wanna do 2 mids do one for say 80-400hz and one for say 400-2500hz, that way they're not fighting each other. i opted for one, nice pair.
as for stretching fleece. i start by stretching over all the rings, the work my way around the 'panel' in a circle. just pull it tight and get rid of any wrinkles.

07-05-2007, 06:05 PM
got my tweets today :) :)
http://img510.imageshack.us/img510/7961/1016639xd3.jpg (http://imageshack.us)
kitty-haired the hell out of it ;)
http://img380.imageshack.us/img380/834/1016642xo0.jpg (http://imageshack.us)
http://img380.imageshack.us/img380/857/1016643mg8.jpg (http://imageshack.us)

07-05-2007, 10:09 PM
I was thinkin about doing this with my 96 prix too, would you suggest I get some panels from the junk yard if its my first glassing project???. I also wanted to do this to the rear decklid, would dynamat keep the metal from rattling against the glass or is there something better, or just as good and cheaper to use. How much did you pay for the glassing supplys to do that on the doors

07-05-2007, 10:13 PM
happy sanding..lol

07-05-2007, 11:26 PM
and what did you use you paint your dash, looks nice got a real deep color

07-05-2007, 11:33 PM
mmmmmmmmm looks like a great! what are ur other plans for the interior?

07-05-2007, 11:52 PM
if this is your first glass job...def get some junkyard panels. there is no way i could of done this on my first job. in fact, my first glass job looked like crap! i might do my rear deck in the future as well ;) the real prob is the torsion bar setup in there they use to hold the trunk open. i still don't know how i'd do it though(the deck) cause i wanna put my subs there, but i don't know how i'd do the box..... but if your just doing the deck for some little speakers that don't require a box, or ib(which i may do) i would bolt it down, either a bolt in the mold that i could put a nut on from in the trunk. or vise versa nut in the mold. i painted the dash w/ 2 stage car paint. i had some left over from when i painted the door. ;)
i have a da, and tons of paper, plus i hit it w/ the roloc discs first...sanding doesn't even bother me:)
as for the rest of the interior. my next project(before the rear deck) is get bucket seats up front, and glass a center console. i'm moving the radio between the seats...but mainly i'm doing this because i'm tired of not having a d@mn cupholder!!!!! :crazy: you know how many sodas i end up wearing! then the deck, and probably alot more i just ain't thought of yet.i was thinking of doing an engine cover...

07-06-2007, 12:31 AM
Well I cant really glass a center console cause my gear selctor is right down the middle, I could redo it to make it look better but so-far as adding gadgets thats outta the question for me, what price for materials would i be looking at to glass the door panels

07-06-2007, 12:50 AM
you got the 2 door? mines a 4 door...my gear selector is on the column. :suave: well my materials were cheap. i have plently of leftovers from my boss's kids' truck http://www.caraudio.com/forum/showthread.php?t=242796
but i'd say ~1/2-3/4 gal resin ($21/gal from boat repair shop up the road) 3-4 yrd mat ($3/yrd) kitty hair ($25/gal my cost from the shop i work at ;) ) lots of time doing it + blood sweat and tears (priceless)
i'm also gonna glass the bottom half of the back doors. not putting anything in them, just glassing them/painting them to match the front doors.

07-06-2007, 04:23 PM
well, im about to go get me some wood and tools and take a crack at building my first box, Pics posted later wish me luck

07-06-2007, 04:29 PM
good luck, and lets see more on this build

07-06-2007, 06:18 PM
i worked on my door for about 2-3hrs today and am not as far as i was yesterday :( i layed another layer of kitty hair over the door...and didn't have enough harderner in it :( so i had to scrape it off. this is where i finished today...
http://img474.imageshack.us/img474/3672/1016648fh1.jpg (http://imageshack.us)

07-06-2007, 06:19 PM
still lookin great, what color are you looking towards paintin it?

07-07-2007, 02:00 AM
I would do it the same as the dash he painted

07-07-2007, 08:31 AM
I would do it the same as the dash he painted

i'm actually repainting the dash when i do the doors. i'm doing everything the new chevy color, its almost the same color, but brighter.

07-07-2007, 11:55 PM
here's what it looks like today. almost done w/ the bondo. i'm having a little trouble getting it smooth under the handle, and where the glassed part meets the top part. hopefully i'll have it taken care of, and primered tommorow.
http://img258.imageshack.us/img258/6821/1016654bj7.jpg (http://imageshack.us)

07-08-2007, 07:34 AM
lookin awsome, cant wait to see it finished

07-08-2007, 11:58 AM
http://img462.imageshack.us/img462/3235/1016657mj9.jpg (http://imageshack.us)

07-09-2007, 08:37 PM
looks really nice!!

07-09-2007, 09:02 PM
lookin real good

07-09-2007, 10:16 PM
made some progress today. got the driverside put in. thats the way its gonna stay till the other side is done, that way i can paint both doors, and the dash all at once. started on the pass side.
http://img241.imageshack.us/img241/536/1016663tj7.jpg (http://imageshack.us)
http://img240.imageshack.us/img240/7388/1016662au9.jpg (http://imageshack.us)

07-09-2007, 10:23 PM
sweet, and are those the tweets you are gonna use?

07-09-2007, 10:28 PM
Sub'd. Nice work so far.

07-09-2007, 10:49 PM
thanks, and no. i got some seas neo tweets in the other day. i'm not installing them till i get time to rewire. i'm adding another amp for the fronts and 2 runs of 14ga to each door and going active :) the re 6.5s are only staying in till i save enough money to get my 7's...heres whats going in my door.

07-10-2007, 02:32 AM
Looks very good. Nice choice on speakers also. Read a lot of good things about those tweets.

I decided to do wooden "pods" for my doors. Sort of like a home speaker baffle look. LOT of fabricating, but it's coming along nicely. Not as smooth looking as a glass install, but I wanted something different.

Looking forward to completed pics.

07-10-2007, 04:14 PM
Wow that sure does look sweet.

07-10-2007, 04:25 PM
Quite busy with the fiberglass I can see.

Good job with all these projects.

07-10-2007, 05:29 PM
that will sound good in there with that equipment

07-12-2007, 10:36 PM
got to work on it a little today, now that my other project is finally done...
i got the rings mounted. this door is gonna be diff than the first, i have the mid and the tweet on the same axis as the first door, so i don't have any side biasing. the mid at about 30-40* and the tweet at 0*. i can't wait, its gonna sound so good!

07-13-2007, 11:10 PM
http://img101.imageshack.us/img101/4936/1016690ox3.jpg (http://imageshack.us)
http://img294.imageshack.us/img294/6002/1016691zi0.jpg (http://imageshack.us)

07-14-2007, 08:53 AM
still looking good, so are the doors gonna be identical?

07-14-2007, 09:43 AM
Excellent job. But MAN you've got that midrange close to your leg, don't you? Did you not want to consider kickpanels at all? I just wonder about alot of your midrange frequencies being blocked by your leg, not to mention the tactility of having a large driver firing that close to your leg. Seems the imaging could be skewed a bit. I'm gonna do something similar in my doors, but for now I've just got 8s mounted with birch baffles. They're not playing midrange, though, I'm running a 3-way active front. When I do mine, i'm gonna have to completely rebuild doorpanels from scratch. :(

Excellent work though. :)

07-14-2007, 09:45 AM
Also, since this is a sealed enclosure, any idea of actual volume?

07-14-2007, 12:48 PM
no, the doors are not identical...but the angle of the speakers are, follow?
i would guess the volume between .3-.5ft, theres actually quite a bit of room in there.

07-14-2007, 12:56 PM
there are several reasons for the build the way i did. kickpanels were not an options...1) i had them in my last car and had a problem w/ people kicking them, i yelled alot, but they still got kicked. 2) the mid and the tweet HAD to be together, and i wasn't fond of the tweet on the floor. 3)i wanted to go sealed, and not near enough room for what i wanted. 4)i just like the way it looks better in the door, than on the floor. i've got my temp re comps mounted in the driver door now, running passive and have got zero problem w/ the mid freq. when i go active i'm crossing them over around 2500, so i feel there will be even less of a problem, as i believe now (passive) they're crossed at ~3500.

07-14-2007, 01:05 PM
Very nice build.
I wanna try something like this when i get a new car worth working on.

Can anyone recommend a place to get spare door panels? places like pick a part that i have seen only have older cars =/

07-14-2007, 01:53 PM
Well, if you can do it, I can glass my doors too o.O...lol.

I've been wanting to, but put it off..maybe I'll try working on some sails!

07-14-2007, 05:29 PM
Probably was asked already but how much resin will you use for both doors?
as stated before a boat repair store but i dont think there are any over here.. homedepot and lowes sell em for 29-31 per gallon last time i checked. Bondo is pretty cheap atleast. If i had a good sander and cutting tools id love to do this project..

Being that i dont shell out just 100$ on materials =/

Ive never knew any good ways to mount glassed object to the car though.. besides bolts but sometimes that doesn't always work.

07-14-2007, 07:58 PM
i used about 1/2-3/4 gal for both doors. they are strong enough that i could lay the panel down and stand on the ring. i only use the air sander on initial sanding, all the rest is hand sanded. carquest wants like $35 a quart. stay away from car stores for the resin ;)

07-14-2007, 08:37 PM
wow i thought it would have been atleast 2 gallons..

how many layers do you have? 2-3?\
carquest = ghey

wish i had an air sander but they require to high cfm and small compressors cant handle that from what i understand.

07-14-2007, 10:39 PM
2 layers on the 'curvy' parts, and 3-4 on the 'flat' parts. i also have about 1/2 gal of kittyhair on the drivers door, and the rest of the gallon left for the pass door. i don't know what they need...i just know at the shop we have a 500 gal tank @ 175psi ;) i can do whatever i want :)

now that i think about it. (i forgot about the inside of the door) i think i used a little over a gall. maybe 1 1/4 gal

07-15-2007, 01:56 AM
500 gal tank at 175psi?

i didnt know they get that big... dude if that got punctured, you would have one hell of a rocket!

07-15-2007, 01:04 PM
500 gal tank at 175psi?

i didnt know they get that big... dude if that got punctured, you would have one hell of a rocket!

i work at a tire shop. that tank runs all the hoists, and our tools ;)

07-18-2007, 09:40 AM
heres the pass door, i got a little work done on it. hope to have it done by this weekend
http://img490.imageshack.us/img490/9135/1016744za5.jpg (http://imageshack.us)

07-18-2007, 05:35 PM
hey jellyfish, i see you posted your car is a 94. i have a 89 grand prix that is a junker with all the interrior pannels in good shape. was wondering if you might be interrested in some parts if they will interchange. looks like they would. email me at [email protected] with any questions or interrests.


07-24-2007, 12:55 AM
well i got the pass side door in. its not primered, or even sanded all the way for that matter, as my 18 came in today, and this project is going to the back burner. the silverado tweet is temp till i run my other wires and install my seas tweets. and my poor re 6.5 met the screwdriver :( i'm glad these were just temp till i bought my 7's that i designed the door around. look forward to my 18 box build in the near future ;)

07-26-2007, 12:05 PM
looks great now i want to do my doors

07-26-2007, 01:04 PM

07-28-2007, 02:42 AM
before clear

07-29-2007, 05:05 PM
well...not to fond of the blue OR the paint job...but here's some pics.

07-29-2007, 05:08 PM

07-29-2007, 05:16 PM
The work looks nice. The paint is a little too wow, but the construction is tops.

07-29-2007, 10:52 PM
ya, its getting redone w/ the green like my dash. the blue didn't go as well as i would have liked. i like the color...it just doesn't belong.

12-26-2007, 08:29 PM
why don't you go for lacquer black or ipod white? the green might look gaudy like the blue but you can bet black will never go out of style

12-27-2007, 01:18 PM
Have you got enough leg room there? In the pics it looks like its moving your leg to one side???

12-28-2007, 08:13 AM
why don't you go for lacquer black or ipod white? the green might look gaudy like the blue but you can bet black will never go out of style

+1 on the black... But I would do a flat black or a textured black. Nothing in that car is laquered or finished smoothly by the looks of it.

Honestly, the interior of that car is nothing special, just primer it, lay a layer of flat black and be done. Enjoy the tunes. :D