Who has constructed their own Flares??

[snb778 5,000+ posts]

I am in the process of making my own flare out of fiberglass, but I don't think its the best way to do it, nor do I think it will turn out how I visioned. Plus I need 6, and thats a lotta fiberglass/resin/bondo/time/paint.. etc etc

Who has made their own flares and how did you do it, ASIDE FROM: rounding over a ring with router

I am trying to make 2x 6" ones, and if im succesful, I want to make an 11" one.

Click to read more...

 

[snb778 5,000+ posts]

ttt??

im thinking of glassing over one of those cheerleading cones that they yell through..??

 

[blackman 10+ year member]

I made a flare once.... Well I caught a field on fire, probly the worlds biggest flare.....oh wait are you talking about flared ports?!

 

[302yota 10+ year member]

if i had any pics, i'd show you how i just attach the pvc pipe to the mdf, cut a hole slightly less than the inner diameter of the pipe, then use a flush trim bit in the router to make the mdf and pvc flush....then just use a roundover bit (size of your choice), and go around the hole to flare it.....if i do another box with aeros this weekend, i'll take some pics, to show you how i do it

 

[snb778 5,000+ posts]

yes, flared aero's ( totally saw that coming though)

 

[amartin_72]

I have constructed my own flares.

I will be constructing more ports tomorrow. This box is for a" 15 HDC3 on aq1200d 4.25ft @35hz 47in port area, 8" diameter port. Going in an 02 cougar hatch for a local kid.

I was testing a new bed liner spray and its not as good as the stuff ive used in the past. So I will sand some more and spray it with the good stuff.

 

[betteraudio 10+ year member]

I too, have constructed my own flares, and though I don't think I have any pics conveniently on hand, I can describe the process somewhat simply for you.

You start by deciding what size and shape you want the throat and mouth of your flare to be. Typically, the mouth is obviously going to be larger than the throat. Once you've made that determination, you can simply cut the openings into your pieces of MDF, and space them however far apart you want, to make the frame.

Next you will take some polyester fleece and staple it smoothly all around the inner edge of the throat, and then stretch through the mouth, pulling the shape tight, and staple it in place. Now simply coat in polyester resin, let it cure, and voila, custom flare. I did, once upon a time, make an enclosure with one flare for the woofer, and two smaller flares for the 2 ports. I'll have to see if I can find any documentation for it.

Being fiberglass, it will have a rather rough finish, on which I recommend sanding down the high spots, and then spraying with a high-fill polyester body filler (basically spray-on bondo, available at a paint and body shop supply house). It's much easier to apply evenly than regular fillers, uses the same MEKP catalyst as the resin, and sands very easily. If you catch it midway through the curing process, when it's somewhat rubbery, and hit it with a 60 or 80 grit paper, the high spots will pretty much just fall off with virtually no effort. I absolutely love the stuff.

 

[mrogowski 5,000+ posts]

Do a search for collo on Google - he will show you how to construct a proper flared port. Very smart and crafty guy.

 

[bubbagumper6 5,000+ posts]

I've heard of people taking PVC, heating it until bendable, and just pushing it down onto the proper sized bowl to flare the end...

 

[plugitin 5,000+ posts]

I've heard of people taking PVC, heating it until bendable, and just pushing it down onto the proper sized bowl to flare the end...

this works, but its quite difficult to heat up a larger diameter piece of pipe and do it, because you need the entire diameter to be hot. it is also sometimes difficult to put enough pressure on the pvc pipe itself to get it to take the form of your mold