I figured it's going to be less effort (for me
to produce plans rather then to arrange production so there it is:
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I used 1/2 inch MDF.
Some pieces have angle cuts - I deemed this necessary in order to get adhesive sealant a space to work thus keep the structure airtight. I am not saying that without these and with plenty of sealant the box wouldn't be airtight, I just don't know.
Upper hole - this is for sub terminal, a $5 item available in most stores including Best Buy installations.
Lower hole - made for the woofer.
Cutting out the original hole in the stock back panel is a must - it is smaller then 8 inch woofer and protrudes towards the box so it would damage the new woofer.
Brace holes (bolts sub to the firewall) - position them according your specific padding. I mentioned that it is vitally important to pad sub from your firewall - and this will affect the exact placement. I used window/door weather stripes - use whatever suits you best.
Sealant - don't use glue, its not gonna work. You need to use sealant also because your pieces will have greater tolerance, remember this is a home made kit and not laser precision cut. So there are going to be clearances between parts and these need to be filled. Glue tends to shrink. Also - the woofer pumps air and creates tremendous stress on the structure - you want the box to be airtight. And you must use nails/screws to support joints. I used adhesive acrylic sealant. Use whatever will work for you but use plenty of it. I put the box together first, let it the adhesive cure and then applied nails.
The most important thing - a subwoofer: There are only several shallow mounts on the market. I used a brand new Kenwood Excelon 8 inch. It might be difficult to get it since it is so new. I paid $200 in local store, online price will be lower, I expect around $120 once available. I can't vouch for any other woofer so don't crucify me in case you won't be satisfied using some B grade. Get the Excelon, currently it's the best shallow mount.
As for my rears - I put there Excelon 4x6. I had to remove the plastic brace which also - in part - supports the roof folded down. The roof however is pretty well fixed by the trunk so there is no real need for that brace. My complete system is:
Headunit - Pioneer Premiere 980BT
Front - Focal 165K2P
Rear - Kenwood Excelon 4x6
Sub - Kenwood Excelon XV800F
Amp - Hertz EP5
So - this is it. I hope I covered everything. Good luck to everyone.
. It's vibrations rivals and exceed those of the engine and exhaust. Best of all the box fits under stock back panel, just need to cut opening for 8inch woofer and add 8inch mesh.
Don't hold out on us..........
