Lightweight Foam Core Sub Enclosure Project

Jayhovah

I figure this has at best a 50% chance of success (defined as - functions and sounds good enough that I choose to use it instead of trashing it), but I am going to try and make a lightweight sub box.. Think it will work? Vote in the poll!

Tentative Enclosure specs:
Zenclosure-style with an Alpine Type R 8"
3" Round Port (Oversized for Alpine Type R 8, to reduce port velocity since I will need to put a sharp bend in it)
Port tuned to 37 Hz (Recommended for Alpine Type R 8)
Net volume ~0.7 ft^3 (Recommended for Alpine Type R 8)

Tentative construction:
Inner layer: FRP tub with plywood mounting ring
Core: 1" rigid foam insulation (pink foam from home depot)
Outter layer: Polyurethane Elastomer (aka polyurea aka 2-part truck bedliner)

I begun yesterday and started construction of a hot-wire foam cutting station. I probably could get away with just using a knife, but I this will make my life easier and will be useful down the road as well! I am using the general design shown in this youtube video:

(as an aside, this guy's videos are awesome)

My version is a little different in terms of size, shape, electronic components, and stand/base design but I ripped 90% of the design from him.

So far I have the base done and the stand roughed out... I'll get some pics up this evening. Hope to finish the cutter sometime in the next week.

This project is going to move at a snails pace.

What do you guys think? Discussion, criticism, and suggestions are all welcome.

__________________
2013 Gun Metallic Sport - Gamma V3 Twin Turbogized
DIY Gamma V3 TT Install * Jayhovah's Gamma V3 TT Install Pic'Z and Vid'Z * DIY: Washer Reservoir for the Boosted