I haven't found any decent pics or write ups on how to do a jack subwoofer installations. At the very least, I'd like to provide my amateur skills and to show you what I have done on mine and to learn from my mistakes. As I am in the building phase currently this will be on going.
So here we go....
This is what I currently have in my car. A single 10" box that takes up about 1/4 of the usual trunk space.
First thing I did was took out anything that was unnecessary. Anything in there has a potential to get resin on it or be an annoyancy. I kept the factory carpet/false floor in place while doing the build.
First thing you have to do is take off the Jack door. I had to trim a few places (youll see when you look). Unfortunately later stage (aka my mistake), I should have taken it right to the lip removing all but the very most outer edge of the jack location. My subwoofer was too wide to fit the location but it also had a protective basket. To note, the stock jack location holds on estimate .65to.70L of space.
Next was I used aluminum tape (1 roll) and I taped about 6" longer than necessary. The reason for this is you want the flattest parts to be on your actual fiberglass box. You will be trimming and shaping later. I taped 4 layers of aluminum tape in a cross hatch pattern in order to make sure there was no sepage into the carpet.
Inside the jack area, you will want to clean the area with alcohol or a degreaser. I then used masking tape inside the jack/wheel well area. Youll see in the pic but from here, I continued and made my own surround with the aluminum tape. Again, making sure to have several layers to ensure it didnt leak and could withstand pressure from the fiberglass.
At this time, you will need to protect everything. It may get messy! Use plastic to cover your seats, double tape all the seams etc. You may think its pointless but if you have resin on your hand or clothes and it gets on your paint or plastics it aint coming off. Next thing to do is use some wax and coat the aluminum foil to make it easier to remove your shell.
Assuming you know how to fiberglass but if not, have plenty of pieces of 4"x2" and 2x2 strips. Any size shape as youll go through them. A helper is usually good as one person fiberglasses and if necessary a helper can bring more if need be. Again, youll want at least 4 layers here; nice and thick. you are aiming to have a 1/4" shell essentially you should be able to walk on it.
After a day or so you should be able to pull it out without difficulty. Keep in mind it will be very tight. Just make sure it is dry.
After some trimming, I was able to fit and secure it. Note the screw. I used an allen head screw, metal washer and rubber washer to hand screw it into place.
At this time youll need to make the face of the box. I used both 1/2" MDF and 3/4" HDF to build up the face.
the outside edges (except the base) are bevelled and the face and the base (of the face) and screwed and glued together. The face is 3/4"+ 1/2". This is strictly to protect the subwoofer.
Hope to have at least some people inspired!