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Old 10th December 2007, 11:37   #31
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Originally Posted by navin View Post
BR, firstly I would use 2 layers of masking tape. this way any excess resin will not flow around it and seep out. Often I found that one layer of masking tape was not enough and that one had to be very careful with resin if only one layer of tape was present.

another thing, you used fiberglass mat, there is another form of fiber glass woven mat that is just as trong and less troublesome to cut and apply as the fibers do not get detached so easily (since it is woven in a symetricla cross weave).

Great job nonetheless.
Yes sir you are correct, I had put 3 layers of masking tape, as resin drips through very easily, sorry i forgot to mention it.
I will definitely try to organise the fiberglass woven mat for my next work, and it makes perfect sense, as I sometimes had a hard time keeping this fiberglass mat tohether with the resin drying so fast.
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Old 10th December 2007, 11:50   #32
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Yes sir you are correct, I had put 3 layers of masking tape, as resin drips through very easily, sorry i forgot to mention it.
I will definitely try to organise the fiberglass woven mat for my next work, and it makes perfect sense, as I sometimes had a hard time keeping this fiberglass mat tohether with the resin drying so fast.
if you find the resin drying too fast reduce the quantity of hardner used. however remember if you increase drying time you will have to control drip for that much longer too. it is a compromise.
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Old 10th December 2007, 11:52   #33
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Excellent job with the fiberglass blueraven.
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Old 10th December 2007, 12:21   #34
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Wonderful job BR.
Congrats.
Zen percent drool job.
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Old 10th December 2007, 13:14   #35
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WOOOAAH! That is a super DIY job, @blueraven!!! You da maan! We collectively doff our hats to you.

1. "Apply resin and hardener to make the fiberglass stick firmly to the doorpad surface till the fiberglass does not become translucent": Did you mean "till the fiberglass mat becomes translucent"?

2. What would be the thickness of the built-up FG? 3mm? 5mm?

3. Did you stick the CC foam sheet before the main FG dried? Or separately with adhesive after it dried?
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Old 10th December 2007, 13:25   #36
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Nice Job Satya .Great finish .

I noticed one thing . As shown by the marking in the pic below , the air space at the point will be enclosed by FP only and not MDF . Will that cause any trouble when you play deep notes at high volume ?
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Old 10th December 2007, 13:32   #37
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Originally Posted by DerAlte View Post
WOOOAAH! That is a super DIY job, @blueraven!!! You da maan! We collectively doff our hats to you.

1. "Apply resin and hardener to make the fiberglass stick firmly to the doorpad surface till the fiberglass does not become translucent": Did you mean "till the fiberglass mat becomes translucent"?

2. What would be the thickness of the built-up FG? 3mm? 5mm?

3. Did you stick the CC foam sheet before the main FG dried? Or separately with adhesive after it dried?
Yes, I meant till the mat becomes transluscent. The thickness is ranging from 2 to 3 MM. The foam is stuck 1 day after the fiberglass is applied, and yes its dry and hard.

Quote:
Originally Posted by maxbhp View Post
Nice Job Satya .Great finish .

I noticed one thing . As shown by the marking in the pic below , the air space at the point will be enclosed by FP only and not MDF . Will that cause any trouble when you play deep notes at high volume ?
No, it's not such an Issue when it comes to speakers, especially entry level speakers, I have not tried any High end components in a setup like this, but don't think it should be an issue even with that. When it comes to subwoofer enclosures, design and build can make or break a system, that is not so critical when it comes to speakers IMO. The acoustics and damping are more critical.
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Old 10th December 2007, 13:46   #38
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Wow this looks Awesome BR, Kudos for the the work & thanks for putting it here in such a nice manner

One query Doesnt all this make the door very heavy ? Wouldnt it cause problems later with door hinges ?
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Old 10th December 2007, 16:23   #39
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Good stuff Cheers

Id seen and smelt this project at different stages, good to see its finally come together. Didnt get a chance to hear it last night, will do soon.
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Old 10th December 2007, 17:05   #40
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awesome job there blueraven !! if you dont mind, i would love to meet you sometime and check out this install where in bangalore are you put up ?
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Old 10th December 2007, 21:51   #41
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Satya! That is one excellent finish. Are you sure, this was your first FG work? ;-)
Your write-up did make me to feel as if the art of building fiber glass mould is so easy, but i am sure it isn't so.
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Old 10th December 2007, 21:53   #42
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Bravo!! Bravo!! Well done indeed. My compliments.
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Old 10th December 2007, 22:00   #43
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Satya, could you please provide the following info:

1) Raw materials bought and quantity used.
2) Amount spent on everything including paint / labour, etc
3) Tools bought / used?
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Old 10th December 2007, 22:35   #44
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Good job sathya, i knew you could do something like this. i appreciate your work ethics.
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Old 10th December 2007, 22:50   #45
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Thanks everyone for the kind words, looks like all that hard work has paid off.

Quote:
Originally Posted by shyamhegde View Post
Satya! That is one excellent finish. Are you sure, this was your first FG work? ;-)
Your write-up did make me to feel as if the art of building fiber glass mould is so easy, but i am sure it isn't so.
He He ! trust me, it's my first FG install ever, few of the guys on the forum who meet me often knew about me trying some experiment from the begining, just did not know then whether it will be install worthy or not. After the first coat of paste I got a good feeling about it.
FG install is not easy, it is hard work, but it's a lot of fun, at least for me, I would love to strip my car system down sometime and build a whole new FG setup, maybe with more designs and some pinstriping job, maybe more, time will tell.

Quote:
Originally Posted by NIP View Post
if you dont mind, i would love to meet you sometime and check out this install where in bangalore are you put up ?
I am put up near Indiranagar, and most of the time am around that area nowadays because of my work, So you can come anytime, just call me a day in advance.

Quote:
Originally Posted by Technocrat View Post
Wow this looks Awesome BR, Kudos for the the work & thanks for putting it here in such a nice manner

One query Doesnt all this make the door very heavy ? Wouldnt it cause problems later with door hinges ?
It's not as heavy as you think it is, the Zen door closes with a nice thunk now, instead of that jarry light tin foil door sound. it's not heavy enough to affect the door hinges definitely.

Quote:
Originally Posted by moralfibre View Post
Satya, could you please provide the following info:

1) Raw materials bought and quantity used.
2) Amount spent on everything including paint / labour, etc
3) Tools bought / used?
Raw Materials:

Fiberglass Mat ( had bought about 40 Sq Ft, 20 Sq Ft went into the mould, 4 doorpads and spare wheel fiberglassing. )
Paste ( Looks white in color and is in powder form, bought 4 Kgs, used 2 kgs I think)
Resin ( Bought 12 litres till date, used 9 litres)
Hardener ( Bought 1 Litre, and I think it will last for a LOONG time)
MDF Wood (Nothing much, just 4 rings cut out in shape and some for the crossovers mounts)
Super glue
Cart Board ( 4 Feet by 4 Feet peice)
Emery Paper ( Don't remember the number, my painter gave it to me)
Some Screws and nails

The raw materials I had given one of my boys to buy, don't remember the individual costs, but totally it was close to Rs 3000.

Paiting Costed me Rs 3000 for the pair of moulds.

Tools
Bosch Drill Machine
Bosch Jigsaw Cutting Machine
Half Round and Flat Wood Files
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