You're right about the hassle of working with fiberglass.
Have fun sanding :)

Got it sanded.. took about an hour and a half. 60 grit paper knocks the filler down pretty fast and I was able to get most of it with a block.

http://www.the370z.com/members/jayho...ler-sanded.jpg

http://www.the370z.com/members/jayho...ler-sanded.jpg

http://www.the370z.com/members/jayho...ler-sanded.jpg

http://www.the370z.com/members/jayho...ler-sanded.jpg

Test fitted it after sanding and cleaning... Looking great.

http://www.the370z.com/members/jayho...9260-putty.jpg

http://www.the370z.com/members/jayho...9259-putty.jpg

http://www.the370z.com/members/jayho...9258-putty.jpg

Started cleaning up some of the bigger voids with some glazing putty... the dimple wasn't filled completely so I tried filling it with the putty. That part really is a job for another coat of filler but I am out of it and don't feel like going out to get more unless I absolutely need it. Most likely, if it drys through properly I will have to put on one more coat of it to get it completely level.

I also decided to glaze the portion that sits against the "bar" as you will be able to see it through that little void.

Hopefully will be able to sand, glaze, and sand one more time and be ready to cover. I also still need to test the seal.

There is a light at the end of the tunnel!

looking good thus far.

Awesome... just so long as it's not a train.

Very nice! You didn't cancel my order did you? :stirthepot:

Thanks!!
No joke! It felt that way when I was about to test fit it... I've had boxes warp on me as I finished them outside the car and you're all excited its taking shape then find out it doesn't fit anymore.
I did, unfortunately. Still waiting on that 165% restocking fee ;)

Sanded the putty, marked the blemishes, and reapplied.

In the dip the putty was still a little soft so I'll let it dry for about 24 hours and give it another quick sanding after work tomorrow. I love how easily the putty sands.

http://www.the370z.com/members/jayho...hes-marked.jpg

http://www.the370z.com/members/jayho...ty-round-2.jpg

Where do I send the $1.65? :tiphat:

Looks great, can't wait to see the finished product. I might have missed this, but how do you plan to anchor it?

BoneZ!!!!!!! The tip about the milkshake is going to be key. I installed the sub, sprayed soapy water all over the enclosure, pressed on the cone and BAM! Imperceptibly tiny pin holes like EVERYWHERE. Will definitely be picking up some extra body filler and resin tomorrow. Can't imagine how this might have affected previous enclosures... though previous enclosures included a lot more layers as they were much much larger.
I have no idea. I am going to wrap the sides with some foam and hope it fits in tightly enough to stay put.

If I anchor it to a panel I'll need to mod the trunk mats to ensure I can access the spare tire.

Awesome. In my experience, I had to use less hardener than I expected. I used the liquid from the resin, not the paste from the Bondo. My first shake turned into a bowling ball before I could get it into the enclosure. Need to keep it flowing for a bit to soak into all the crannies.

Thanks! Did you mix 50/50? What consistency did you go for? Runny at all? Or just tilt the box and watch it slowly slide around?

I've also thinned body filler down with acetone in the past and it works GREAT. I could probably get it much thinner than I could with resin but I may go with the resin just for the added stiffness.

I just added Bondo to the resin until it created a thick yet decent flowing consistency. Definitely thin enough to flow around the Box when tilted.

Question from the audio challenged. I know you're fabricating a sealed enclosure but is it critical to seal the pin holes?

For sure!! I have seen cones tear from the resistance of having to push/pull air through the pin holes. Even if it isn't that catastrophic, it's going to distort the sound.