I do alot of custom fiberglass work.
What you need to do is first create a "wireframe" for your box out of mdf(or something else) (which you may have already done) then you take "Polar Fleece" and stretch it over the desired area (this will allow smooth transition lines instead of harsh corners).
You then mix up a vat of resin and 'paint' the cloth with the resin and wait till it cures, do this a couple more times then re-enforce week areas with 1 or 2 layers of fibercloth and then put 1 layer of fiberglass re-enforced body filler, then 1 layer of regular filler and then sand, then paint, then clear, then polish
(re-apply any step where needed)
Polar Fleece is the best to use because it will stretch both ways and is very absorbant so it will absorb alot of resin.
If done properly the box will be strong enough to allow 2 - 200lb people to stand on it - will not flex when the bass hits - will be extremely light compared to the mdf counterpart and - will also alow for near exact box size measurements.
Hope this will help, if you have anymore Q's feel free to ask
Jeff
As far as i am doing mine it will be wood framed to have an even frame and let the body filler do the shaping.
Linear Mode
