F1Addict
08-25-2013, 04:18 PM
One of the first projects I tackled after getting my XJ in late 2011 was to fabricate a subwoofer box. I'd been driving around for a couple months with a big enclosure floating around in the cargo area and was growing tired of having to remove or reposition it every time I needed to use the space for... stuff. I looked all over the interwebs in search of an elegant solution but never really found anything that didn't look like a hack job or an incomplete attempt. So, I designed and built my own. That doesn't mean there aren't some great designs out there, I just never found any that fit my needs.
The first step was to determine the amount of volume needed for my 12" Eclipse sub with a sealed enclosure. 1.2 ft³ was the answer. In order to achieve that volume I would have to utilize the space within the rear fenderwell which meant I would have to trim the inner quarter panel, something I wasn't thrilled about.
Next up, I created hard-board templates for all the complex curves of the metal structure behind the plastic quarter panel. Then it was time to start fabricating.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5711_mod_CF600.jpg
It was tedious work. The box was to serve three purposes. First was the sub enclosure which would have to be acoustically isolated and sealed from the rest of the structure. Second was that I wanted it to incorporate a standard 120v outlet that would be linked to my 1000w inverter and finally, I wanted at least a little storage space for all those little things that tend to rattle around back there without a home.
I built the sub enclosure so that it hugged the inner wheel well and extended to within about 1 inch of the outer fender skin, that was the only way to get the volume I needed.
This was my first test fit so I guess I was pretty close with my template...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5601.jpg
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5591.jpg
I had to notch the top a little to accommodate the rear seatback.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5602.jpg
Inside the storage area.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5595.jpg
Storage lid closed...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5593.jpg
Storage lid open (my old, bulky, inconvenient sub enclosure can be seen taking up all my cargo space)...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5588.jpg
I cut the trailing edge of the lid at an angle so that when it was open it perfectly matched the forward-swept angle of the D pillar and would open into the window space without hitting the pillar. It doesn't necessarily look that way in this picture but further down you can see the matching angle with a more straigh-on view of the open lid.
With the fit confirmed, it was time to make it pretty. I used flat black rattle can to paint the areas where carpet seams would be. That way my lack of carpeting skills would be less obvious and if there was a tiny gap in fit the black paint would hide the seam.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5715_CF600.jpg
Here's a closer look at the assembled sub enclosure area (from the back)
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5716_CF600.jpg
I then covered the whole thing with a roll of black interior carpet I picked up at O'Reilly's for around $15. I used 3M spray adhesive to attach it. A year later and my feet still stick to the garage floor in the area where I sticky-sprayed the project. I recommend laying out newspaper or felt paper before spraying.
After I got the carpet stuck on, I focused my attention on the 120v outlet. I used a standard single-gang old work box. I considered using a GFI outlet but the inverter has GFI protection built in so it would be redundant and more expensive. Why bother?
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5770_CF600.jpg
Here is the final product...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5730_CF600.jpg
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5729_CF600.jpg
With the inverter hooked up, this picture is lit by fluorescent photo lights plugged into the outlet located in the box.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5748_CF600.jpg
The box is made from 3/4" ULMDF (ultra light MDF) and weighs just 9 pounds (without the sub, obviously). All joints are glued and screwed. I didn't bother filling the screw holes knowing they would be covered by the carpet but if you were going to bedline it or paint rather than carpet you could fill the holes for aesthetics or leave them exposed for a more industrial look. The project took about 50 hours to complete and total materials cost was about $100 including: 4'x8'x3/4" ULMDF, 2 LB. 1 5/8" ceramic coated deck screws, Krylon flat black rattle can, black carpet, 3M spray adhesive, quick-connect speaker terminals, single-gang old work electric box and single gang 120v outlet with cover plate.
My next project will be to make a matching-ish box for the other side that will be dedicated to storage. I've since purchased a 2000w pure sine wave inverter that's too large to mount anywhere in my Jeep. I'll also be incorporating an insulated compressor compartment for my future lockers and general storage. It will also allow me to install a small, retractable sun shade between the two boxes to cover the cargo area.
Sadly, there is a lot of free-style creativity in this project so I don't have any plans drawn up but if you're creative and ambitious enough to tackle something similar, I hope the pictures and write-up will be of value.
The first step was to determine the amount of volume needed for my 12" Eclipse sub with a sealed enclosure. 1.2 ft³ was the answer. In order to achieve that volume I would have to utilize the space within the rear fenderwell which meant I would have to trim the inner quarter panel, something I wasn't thrilled about.
Next up, I created hard-board templates for all the complex curves of the metal structure behind the plastic quarter panel. Then it was time to start fabricating.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5711_mod_CF600.jpg
It was tedious work. The box was to serve three purposes. First was the sub enclosure which would have to be acoustically isolated and sealed from the rest of the structure. Second was that I wanted it to incorporate a standard 120v outlet that would be linked to my 1000w inverter and finally, I wanted at least a little storage space for all those little things that tend to rattle around back there without a home.
I built the sub enclosure so that it hugged the inner wheel well and extended to within about 1 inch of the outer fender skin, that was the only way to get the volume I needed.
This was my first test fit so I guess I was pretty close with my template...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5601.jpg
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5591.jpg
I had to notch the top a little to accommodate the rear seatback.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5602.jpg
Inside the storage area.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5595.jpg
Storage lid closed...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5593.jpg
Storage lid open (my old, bulky, inconvenient sub enclosure can be seen taking up all my cargo space)...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5588.jpg
I cut the trailing edge of the lid at an angle so that when it was open it perfectly matched the forward-swept angle of the D pillar and would open into the window space without hitting the pillar. It doesn't necessarily look that way in this picture but further down you can see the matching angle with a more straigh-on view of the open lid.
With the fit confirmed, it was time to make it pretty. I used flat black rattle can to paint the areas where carpet seams would be. That way my lack of carpeting skills would be less obvious and if there was a tiny gap in fit the black paint would hide the seam.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5715_CF600.jpg
Here's a closer look at the assembled sub enclosure area (from the back)
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5716_CF600.jpg
I then covered the whole thing with a roll of black interior carpet I picked up at O'Reilly's for around $15. I used 3M spray adhesive to attach it. A year later and my feet still stick to the garage floor in the area where I sticky-sprayed the project. I recommend laying out newspaper or felt paper before spraying.
After I got the carpet stuck on, I focused my attention on the 120v outlet. I used a standard single-gang old work box. I considered using a GFI outlet but the inverter has GFI protection built in so it would be redundant and more expensive. Why bother?
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5770_CF600.jpg
Here is the final product...
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5730_CF600.jpg
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5729_CF600.jpg
With the inverter hooked up, this picture is lit by fluorescent photo lights plugged into the outlet located in the box.
http://i140.photobucket.com/albums/r34/F1Addict/Jeep/IMG_5748_CF600.jpg
The box is made from 3/4" ULMDF (ultra light MDF) and weighs just 9 pounds (without the sub, obviously). All joints are glued and screwed. I didn't bother filling the screw holes knowing they would be covered by the carpet but if you were going to bedline it or paint rather than carpet you could fill the holes for aesthetics or leave them exposed for a more industrial look. The project took about 50 hours to complete and total materials cost was about $100 including: 4'x8'x3/4" ULMDF, 2 LB. 1 5/8" ceramic coated deck screws, Krylon flat black rattle can, black carpet, 3M spray adhesive, quick-connect speaker terminals, single-gang old work electric box and single gang 120v outlet with cover plate.
My next project will be to make a matching-ish box for the other side that will be dedicated to storage. I've since purchased a 2000w pure sine wave inverter that's too large to mount anywhere in my Jeep. I'll also be incorporating an insulated compressor compartment for my future lockers and general storage. It will also allow me to install a small, retractable sun shade between the two boxes to cover the cargo area.
Sadly, there is a lot of free-style creativity in this project so I don't have any plans drawn up but if you're creative and ambitious enough to tackle something similar, I hope the pictures and write-up will be of value.