if i was to make them again, once i had the fibreglass frame i would make the shape with expanding foam, cut it too shape which is very easy, then put some resin over it then a skim of filler, very easy to do.

I'd certainly suggest another layer of fibreglass matting to make it more solid. If you use the fibreglass paste on it would make the build heavier. Using sheets cuts down on the weight.
Use an orbital sander on the dried matting to get the rough edges off, then use bodyfiller to get the smooth finish.
As smooth as you can too no matter whats covering them. Things will sink after time. Its not the smooth finish thats a problem though with these things, its getting the level finish thats a pain. You get dips and ripples and its these that cause the problem.
As for the foam, the idea is right, filling the space behind, but I would tend to go for the wadding TBH. Thats what I'm gonna use any ways. Components and mids need air and if you fill the hole behind, you'll be cutting down on that. Using wadding dampens the sound for that quality, but doesnt exhaust it like the foam might. If you put too much foam in, it'll be a twat to dig out. You can add or take away with wadding.
All thats left is LOADS OF SANDING :! :! :!
Be prepared cause it takes forever :(

Claire

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Originally posted by CheekyCorsa

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Originally posted by LiVe LeE
Beardy: Cavity wall foam, where should i put that:boggle:

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Originally posted by BeArDy

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Originally posted by CheekyCorsa

This is only bit that worries me as abit hollow:(

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:wave:

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Originally posted by CheekyCorsa

This is only bit that worries me as abit hollow:(

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just checking :lol:

Yes i do have leccy window:lol:

ow yeah forgot to say i hope you have electric windows :lol:

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Originally posted by antonOO2
very nice ,lot of work gone into them i bet .also i have the same duvet :lol: :thumbs:

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very nice ,lot of work gone into them i bet .also i have the same duvet :lol: :thumbs:

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Originally posted by LiVe LeE
still good to get it near perfect - as after a whiel ur alcantara will pull away from the lwo spots and leave sags - get it smooth as possible for the finish

how do u plan to cover the inside of the pocket - Im starting my door build hopefully in a few weeks b4 donny, and thinking spraying them - as I cant figure out how to cover inside the pocket and make it look good

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Looking Good Matey :)

still good to get it near perfect - as after a whiel ur alcantara will pull away from the lwo spots and leave sags - get it smooth as possible for the finish

how do u plan to cover the inside of the pocket - Im starting my door build hopefully in a few weeks b4 donny, and thinking spraying them - as I cant figure out how to cover inside the pocket and make it look good

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Originally posted by LiVe LeE
Sand it up first - to find high and low spots - then use P40 - fibreglass filler to fill the gaps, continue to sand an fill till u get a top notch glass finish.

The filler is basically chop strand matt, in a resin , but already chopped - so not in matt form nemore. use that and u should get a good all round finsih - but looking good so far

what speakers are going in

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Cavity wall foam ;)

Sand it up first - to find high and low spots - then use P40 - fibreglass filler to fill the gaps, continue to sand an fill till u get a top notch glass finish.

The filler is basically chop strand matt, in a resin , but already chopped - so not in matt form nemore. use that and u should get a good all round finsih - but looking good so far

what speakers are going in

Heres a few piccys of my door builds;)



This is only bit that worries me as abit hollow:(


Right what do i do next they have 1 layer of matting on them and i know it wouldnt be to hard to add 1 or 2 more but looking at them and tidying them up i personally dont think that they really need it, but im no fibreglass expert at all and this is my frst ever attempt:0

So im looking for some advice please:D