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Satya, it's Beautiful, to say the least. And an excellent report - made it easy to understand how you did it.

Is it possible to shape the mould so that it matches the contours of the door-pad it is mounted on ?

Top class work, buddy! And a great tutorial. You da man!

Anwar had better watch out now :)

Looking forward to seeing more and more stuff like this from you!

Well Done Satya:Cheering:. The finished product looks mind-blowing. A very nice report for a DIY-er, thanks for sharing with us.

Congrats Satya! The quality is simply awesome, It makes it all the more beautiful considering its your first DIY fiberglass install... clap:

Couple of quick questions.

1) I assume you made 2 moulds for the 2 doors. If so how did you ensure that the mould shape remained identical for both cases? The outer dimensions can be measured and made accurate. What about the curves, depressions and elevations within/on the surface? Did you rely solely on your visual judgment or is there a way to measure and ensure?


2) For the Resin, Hardener and Fiberglass, could you post the company name, price and where you procured them from?.

Superb work blueraven....really really good!

i had a privilege of seeing and hearing the setup on saturday. man does it sounds goood. it was mind blowing and the finish was tooo good.. good work done Satya..

Yeah fiberglass moulds can be shaped in any way, as long as the mould acomodates the speaker's magnet within or mods are done on the doorpad to acomodate otherwise. But yes, thats the fun with working on fiberglass, it takes quite a bit of labour, but the final output is proportional.

Thanks Hyrda,
He saw the setup the first day it was done, he was happy with the work and gave me some suggestions too, besides he is a very senior Installer, and this is some really small stuff, I have seen some works by Anwar, and myself would be very satisfied if I can do some setups with the fit and finish and sound like he delivers. Only time will tell.

Superb job bluevaren,looks amazing

It looks great! Good job and writeup :)

u are one mad mad mad person and i really like that, even im like that

1) Thw two moulds were built together, the base was made keeping the first base as a template, equal sized rings were made and the angle of the mount was determined with placement using MDF, there is part measurement, part visual judgement involved. The shape and curves is ensured only by visual judgement and how the cloth is wrapped around the mould.

2) I made my painter pick up the stuff from market, there is no company as such, Resin comes in 5 litre cans, hardener in 2 litre cans. I used up 8 litlres of resin in this setup including the doorpads and spare wheel which is coated with fiberglass too. The total material cost was around Rs 3000.

fantastic stuff dear

Great job, Mr. Satyajit Dutt

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.