For this video, we are going over the steps to create a set of subwoofer boxes for the S550 (2015-2023) Mustang from start to finish. This is the second build; the first set came out ok, but not perfect.
========== Plug Creation ==========
1. Intro - 0:01
2. Creating The Shape - 2:38
3. Sand Foam Surface - 5:12
4. Cutoff MDF Board - 6:10
5. Fiberglass Foam Surface - 12:56
6. Attach MDF Boards - 14:32
7. Fill Plug Gaps - 17:07
8. Primer Surface - 22:29
9. Wetsand Primer - 23:00
10. Clear Coat Surface - 26:02
========== Mold Forming ==========
11. Attach Flange Material - 26:51
12. Fill In Mold Gaps - 27:46
13. Apply Mold Release Paste Wax - 28:59
14. Apply Mold Release Agent - 29:47
15. Apply Tooling Gel Coat - 30:17
16. Layup 30gsm Fiberglass - 32:32
17. Layup .75oz Fiberglass - 33:13
18. Layup 1.5oz Fiberglass - 34:30
19. Layup 1.5oz Fiberglass w/Wax) - 36:05
20. Add Mold Supports - 37:19
21. Trim Mold Edges - 39:29
22. Demold Plug - 40:05
23. Clean Mold - 42:42
24. Wetsand Mold - 43:19
25. Polish Mold - 44:12
========== Part Making ==========
26. Apply Mold Release Paste Wax - 45:00
27. Apply Mold Release Agent - 45:38
28. Apply Gel Coat - 45:58
29. Layup 30gsm Fiberglass - 46:50
30. Layup .75oz Fiberglass - 47:30
31. Layup 1.5oz Fiberglass w/Wax - 48:29
32. Demold Part - 49:27
33. Clean Part - 50:51
34. Trim Off The Flange - 51:32
35. Sand Edges - 51:51
36. Cutoff Front Boards - 52:57
37. Cutoff Speaker Rings - 55:16
38. Attach Rings - 56:46
39. Attach Front Boards - 1:00:43
40. Attach Carpet - 1:05:17
41. Add Polyester Stuffing - 1:12:45
42. Install Speakers/Acc - 1:13:26
43. Final Product - 1:15:53
Products Used:
This video contains affiliate links for which I may receive compensation.
========== Fiberglass Material ==========
Polyester Resin (AC8040N-2K) - easternburlap.com/products/
Tooling Gelcoat (AC379T-2K)
Fiberglass Mat 3/4 OZ., 50" WIDE (OC-7550)
Fiberglass Mat 1.5 OZ., 50" WIDE (OC-1550)
Wax Surfacing Agent (AC2290-1)
Fiberglass 30gsm, 5mx1m - www.ebay.com/itm/304011296765
Partall Paste #2 - amzn.to/42euVO0
Partall Film #10 - amzn.to/3Sa4jJa
Pour Foam - amzn.to/4gS0Fyj
Plastic Sign - www.lowes.com/pd/Hillman-24-in-x-36-in-Blank-Sign/3340838
MDF Board (723984) - www.lowes.com/pd/MDF-Actual-0-5-in-x-24-in-x-4-ft/1000080511
========== Disposable Material ==========
3M Marine Adhesive Sealant Fast Cure 5200 - amzn.to/3BI8VlH
3M Super 77 Multipurpose Spray Adhesive - amzn.to/3VXDWcl
Sanding Discs - amzn.to/3It0POi
Body Filler - amzn.to/4fCO3dB
Chip Brushes - amzn.to/3UbybaC
Clear Acrylic Enamel - www.harborfreight.com/11-oz-gloss-crystal-clear-acrylic-enamel-spray-paint-67939.html
Eye Dropper - amzn.to/48PZjAz
Glass Fiberglass Filler - amzn.to/4a2CPhi
Glazing & Spot Putty - amzn.to/3ZVstLd
Glue Sticks - amzn.to/427ziub
J-B Weld Epoxy - amzn.to/41Q3ewA
Ultimate Compound - amzn.to/3Sn29qW
Mixing Cups - amzn.to/3OfHFOk
Nitrile Gloves - amzn.to/3lABI38
Polyester Tape - amzn.to/48Iq8Xp
Primer - www.harborfreight.com/11-oz-gray-filler-primer-spray-paint-67968.html
Sanding Drum Set - amzn.to/3EcSYSp
Sandpaper 60-5000 Grit - amzn.to/3u3M8g7
Wood Sticks - amzn.to/3Pj3rkg
========== Speaker Box Material ==========
Speaker Box Terminal - amzn.to/49TIfea
M4 x 25MM Screws - amzn.to/3DIgb1k
MTX Audio 3510-04 Subwoofer - amzn.to/3PcZqhq
Polyester Stuffing - www.crutchfield.com/p_027808/Polyester-Fiber-Stuffing-1-pound-pack.html
Threaded Insert (M4) - amzn.to/49TIypk
Carpet (542050) - www.hobbylobby.com/fabric-sewing/utility-fabrics/felt-fabric/charcoal-felt-fabric/p/45161
========== Misc Products ==========
Applicator Pad - amzn.to/47PewAG
Glue Gun - amzn.to/3XOqXrm
HVLP Spray Gun - amzn.to/3OmsjI3
Respirator Mask - amzn.to/3SFpg04
Trim Removal Tool Set - amzn.to/3hRQA8j
Wire Terminal Crimping Tool Kit - amzn.to/3BYeUml
xTool P2 - amzn.to/4gQ6Hzn
#SpeakerBoxBuild
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