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Front showing Orciari headlights and custom wheels
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Center dash with Audio Control 4.1 EQ/Line Driver, repainted to match the door panel silver.
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View from the driver's seat. 6-1/2" Polk/MOMO component systems were molded into the doors. I decided to take the pocket OUT (just a trash collector anyway)
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Fiberglass subwoofer enclosure. (2) 12" Polk/MOMO drivers with an Alpine MRV-T757 amp in the center.
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Another angle, you can see the alpine amp molded in the left side of the trunk.
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Closeup of the custom 5-star wheels.
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Step 1: Cut it out, glass it up
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Not very pretty. The next step is to add body filler to smooth out the surface.
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Body filler with fiberglass reinforcement
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I got a lot of sanding to do.
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Almost done, my arm is about to fall off right about now from all the damn sanding.
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Thicker primer to put on top of the body filler.
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Thin coat of primer to get into all the scratches out, then sanded smooth.
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Open-door shot of the door panels after paint.
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First, the 12" subwoofer mounting rings were cut out and glued into place. The frame was made out of 3/4" MDF.
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The amp will be mounted between the two subwoofers, so a flat back was glued at an angle behind the rings.
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Carpet was stretched and hot-glued to the outer rings. The carpet was then soaked with fiberglass and then I applied fiberglass to fiberglass mat to re-enforce the inside of the box.
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I used zip ties to make the curve from woofer ring to the amp back. I had to make sure that the amp fit nicely in the middle. A small strip of MDF was used for the amp to rest on and to hide the power cable connections.
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Test fit the amp to make sure there was plenty of room for it to fit. The power connections to the amp will just be drilled into the bottom of the box.
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After the fiberglass dried, I applied body filler (the green) and started the sanding process.
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Here's a look at the body filler and how it was applied. You won't see the top-middle where the amp will be, so no body filler was needed.
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Another front view of the box in the sanding/filler process. This took forever to get smooth.
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Test fit into the trunk. You can image now how it will look when finished. The amp sits nicely in the middle, with the lights, fan, and audio controls visible.
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After all the sanding and sanding and sanding, it finally was ready for some paint. Here's a shot of the finished product.
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Here is a really close-up picture of a " W" in a wrx logo that I had made. You can see each layer in the building process. I took the picture on lined notebook paper, you can also see through it.
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These grilles were made by our SLA machine (Stereo Lithography Apparatus). It's basically a prototyping machine. You put in .stl file generated from Pro-Engineer, it builds (using liquid goo and lasers -- COOL!) anything you want.
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Close up of the custom SLA grilles
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