I am working on a box for 4 12" Alpine type Rs for my cousin's 04' Explorer and Kinda doing this same thing...
So we built the box out of MDF and got it the way we wanted it. Now come time to cover it... I wanted her to do it in vinyl to match her interior her B/F wanted it done in carpet.... So we comprermised, Back, top and sides are carpet, fromt will be painted to match the trucks exterior...
Basicly, I had the front baffle cut and shaped the way I wanted it. So I mixed up a the resin and catalyst (in mixing bowl $1.00ea from Home depo, right next to the resin). I used a tac rag for painting cars to wipe down the surface, making sure there was'nt any dust or debree. Then I applied a thin coat of Resin. I let it try for a half hour or so and layed on another. I think I put on three maybe four thin coats. Then I sanded down all the high spots (I think I was using 220 grit) and layed on a final coat of resin. It took a bit more sanding then I primered it. I used 3 good coats of primer. Then I sanded that all smooth (with 550 grit) tell I was happy. Now come the paint. I layed on three coats of paint. So far it looks good. I haven't had anymore time to mess with it. I still have too clear it a few times and buff the piss out of it...
I have a few pics of the box under construction and when I get it finished I will take a few more and post them if you like...
Overall, I'm happy with the Boxs construction and the ampracks sliding drawer for the 4 amps, but I am not really happy with the Carpeting. That was not my idea, I wanted Vinyl, I think it would have complemented the Explorer's interior much better and the paint would have just set it off... O'well, not my ride... We'll see how it turns out...
Sorry so long, Hope that all helps...