how should i do my blow thru?

we need to know the vehicle make/model/year.

assuming it's a standard cab pickup truck:

you need to be comfortable making permanent large holes in your truck that will severely affect resale.

the idea is to seal off the front of the sub box baffle with the cab. you also need to maintain some flexibility between the cab and truck bed. they are two separate pieces for a reason.

first step is designing and building the sub enclosure. once you have that done then you have the dimensions for your blow-through. you need t decide how you want to connect the baffle to the cab. this has been done in a variety of ways - some more successful than others.

i recommend that you or your installer have access to, and the ability to use, a welder. you'll want to weld some L-channel around the opening to stiffen it and give yourself a place to secure the box and seals. if you cannot get welding done right, don't do this project. if you cannot cut straight lines in metal - don't do this project. fiberglass is commonly used to make a new panel to frame the opening, though you can use wood, resin, and carpeting if you cannot fiberglass. construction alone will run you hundreds of dollars to DIY, and over a grand to pay someone.

the box will be in the bed and exposed to the elements. a fiberglass tonneau cover is commonly used to protect the bed/enclosure - meaning a reduction in usefulness of the truck bed. also, the enclosure will need to be waterproof - resin or bedliner have been used to protect and coat the wooded box.

in order to maintain flexiblity between the cab and bed - rubber seals have been used - in varying ways with varying success.

do some searches on forums for build logs involving a blow-through, there are several on Car Domain. Ideally, you'd find some on the same make/model of your vehicle.

 
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