Rockford-Fosgate, Polk Audio, JL Audio, Exile Audio - And so the install begins

[nemalibu]

Nope, this was just made 2 days ago. 1.2 cu.ft. for my Exile 12" in my 2012 VLX with heater.

Very nice. I am being stubborn and keeping the kick plate in the original place and at the original angle. It is making the box more complicated but I am hoping I will be happier in the end - only time will tell. In any case, working on the boat when I can't be out on her is therapeutic for me.

[dalt1]

Very nice. I am being stubborn and keeping the kick plate in the original place and at the original angle. It is making the box more complicated but I am hoping I will be happier in the end - only time will tell. In any case, working on the boat when I can't be out on her is therapeutic for me.

My kick plate will be in the original position at the floor but stood up straight instead of tilted toward front of boat as in stock position.

[dalt1]

http://www.kommerlingusa.com/komacel/technical.cfml

Plan on using this material for my sub box, anyone see any problems or better material suggestions, I can buy this local. It can be solvent welded at seams to seal it good, like PVC pipe.

[David]

It depends. I wouldn't use any material for a larger sub enclosure unless it was 0.625" thick or thicker. Maybe only 0.50" dense fiberglass mat.

With 0.50" thick polymers you would need a LOT of internal bracing structure. 0.375" is just too thin in any case.

The other property worth considering is how acoustically live or inert it is.

[dalt1]

It depends. I wouldn't use any material for a larger sub enclosure unless it was 0.625" thick or thicker. Maybe only 0.50" dense fiberglass mat.

With 0.50" thick polymers you would need a LOT of internal bracing structure. 0.375" is just too thin in any case.

The other property worth considering is how acoustically live or inert it is.

This would be .750" thick material. It shows larger thicknesses on right side of stat sheet.

Edited January 2, 2015 by dalt1

[nemalibu]

I going with Baltic Birch Marine Plywood. I was able to order it online from Capitol City

Lumber. Should be to me on Monday.

[Cory]

I would avoid the finger joints on any surface joints that aren't right angles. I'd limit your joint types to dado joints or rabbit joints on right angles. The rest just use a butt joint, glue, clamps, and finish nails. A clean cut, well clamped glue joint is not joining to fail.

Edited January 12, 2015 by Cory

[nemalibu]

Too late. All parts are cut. The box assembly is almost complete. The box is basically indestructible with all those interlocking finger joints.

[nemalibu]

The box pieces are cut and I am performing a fit check. Then I will glue and screw.

[ajeep4u]

We call my dad "mister overkill" and I think you have him beat! I like it! I wouldn't do it. Too lazy and have had good luck with regular joints and glue, but enjoying the pics! Keep em coming.

Edited January 10, 2015 by ajeep4u

[Cory]

Wow!!!

[nemalibu]

Now it is glued and screwed (with around 100 screws) and I cut a 5" hole near where the sub driver will go so that I could reach inside and caulk the bottom (it went on last).

Next I will be paining it with truck bed liner.

[nemalibu]

Doing a final check of the fit of the box in the boat.

[ahopkins22LSV]

Pretty impressive box. How did you make sure that the joints that are not 90 degree seal well? Maybe it's just my head but I don't seem to understand how the joint could seal well being on a slight angle.

[nemalibu]

First it is worth noting that this was designed in 3D with SolidWorks. Possibly the only way to get it right the first time.

For the non 90 degree joints, cut one side of the joint a bit deep to take up the extra needed. Then sand off the protruding fingers after the box is together.

For the entire box, apply glue to all joints during assembly and then put a bead of silicone along the inside edge before putting the bottom on. Then I cut a 5" hole near where the driver will go so that I could reach inside and put down a bead along the bottom seems.

Then for complete overkill, I applied truck bed liner coating to the outside of the box (the box is not yet coated in the pictures I have shown).

Edited January 11, 2015 by nemalibu

[Bawshogg]

Wierd man, wierd.

[NorrisMike]

Now it is glued and screwed (with around 100 screws) and I cut a 5" hole near where the sub driver will go so that I could reach inside and caulk the bottom (it went on last).

Next I will be paining it with truck bed liner.

A single male/female tab on each side would have been plenty to aid in assembly - I applaud your effort! Sure does look cool.

[Cory]

I'm curious how you got the CAD design to wood? Did you print out templates and trace onto the wood? I assume you have a jig for your router to accomplish those finger joints, but lining everything up just right (without at least a paper template) would still be tricky.

Or, do you have access to fancy industrial machinery where you feed in the plywood and out comes all the pieces pre-cut according to the CAD design?

[ahopkins22LSV]

Looks laser cut to me. (burnt edges)

[Cory]

I was wondering why those edges were black. This guy must have access to equipment I could only dream about.

I often dream about having Superman's laser vision eyes--usually when I'm topping the trees in my backyard. Sure would be nice just to look at the branch I want gone. I suppose laser vision would take visualizing your goal in the wood medium to a new level.

Edited January 12, 2015 by Cory

[hunter77ah]

I love overkill and I have access to a 1 kW laser flatbed cutter.

Looks laser cut to me. (burnt edges)

[ahopkins22LSV]

Ah, well I didn't read the whole thread

[nemalibu]

Here is a short video showing the machine cutting part of the box. The cut speed is 300 "/min.

Edited January 13, 2015 by nemalibu

[shawndoggy]

I'd like the home version of that machine, please.

[IXFE]

How big is your home? We have had customers put the somewhat slower version in their homes. Note the slower one goes for around $100k.

Can you find a cheaper version at Harbor Freight?

Just asking...