well i see we have a kick panel guide and not a door pod guide. just went and completed this pod http://www.caraudio.com/forum/showth...83#post1880683 and already have people asking questions so i thought it would be a good idea to put it all together in one thread, with some explainations. Now i'm a **** poor glasser so if you got better skills, your will turn out even better. also not gonna get into how to actually lay fiberglass. there are good tutorials where you can learn how to glass.
first you will start off by cutting a hole in you door panel. now you want to follow the same contour of you door panel. don't just cut a 8" round hole or whatever. make sure the hole is big enough though for your speaker.
since you are actually building a sealed enclosure to mount to you door, you need something to anchor it too. on the outer doorskin, i mounted a piece of wood in which the pod itself will mount to. doesn't need to be thick or mdf. i just used some 1/2" osb scrap i had. you can use aluminum or whatever. just make sure it is sturdy
now you want to put masking tape around the entire hole, going a good 6 or so inches out.
now you can take some aluminum foil and put it in the hole and stretch it out 6 or so inches along with the asking tape and you can either hot glue or use spray adheisive to adhere it to the tape
now, preferably with the same wood, you'll use the piece of the door panel you cut out to trace onto a piece of wood, the same shape of your hole, but about 1/2 to 1 inch smaller. this will eventually be the back of your pod
now i used some fleece i picked up for walmart as the backing material. it wasn't too thick nor too thin. i measure side to side and top to bottom of the area i taped and added a few inches for inside the hole. i then took those measurements and cut out a piece of fleece. imo it's easier to handle when it is stretched tight on the back of that wood you cut.
now take your wood and you can hot glue, try to get as close to the edge as possible, and glue it to the stretched fleece
a little tip. pre drill one hole in the wood before you glue it to the fleece. then after you glue it to the fleece, cut the fleece around where the hole is. that way when you mount the wood, the screw won't rip the **** out of the fleece
now you mount that board in the hole. (i'm assuming you had the common sense to test fit it before gluing to the fleece. when doing these always test fit before you move on ) then stretch the fleece out from the back of the wood onto the door panel where you applied the foil, using an adhesive. mine started to wrinkle so i made a relief cut. wrinkles are too big of a deal since you don't see this part when you are done, but try to keep them to a minimum
now trim away excess material
now time for the resin. imo with fiberglass, it is always easier to do if you have a good workstation. i like to be chest level so you see i have a stool to sit on, and i set up a make-shift work bench with jack stands and plywood. all the materials i need are setup and no excess materials are there to clutter up the area