Fiberglass custom speaker enclosures can hide your ugly speakers.
Fiberglass makes an ideal material for creating an unobtrusive speaker enclosure in your home. You can make the enclosure virtually any shape you want to fit any size speaker you want. You can make it look like a rock, a plant stand or even part of the wall. Simply create a mold and lay the fiberglass and resin over it to make the box. When set, you can cut out holes for wires to pass through for insetting the speaker grille.
Instructions
1. Trim a large Styrofoam block to the shape of the speaker enclosure with the grinding or rotary cutting tool. Trim down the block till it fits precisely where you want it to and is the shape you desire. The block will be the form for making your fiberglass container. Cover the Styrofoam form with plastic to prevent the fiberglass from adhering to the Styrofoam.
2. Lay fiberglass sheet over the Styrofoam block. Cut and trim it to size with scissors and pin the fiberglass in place with thumbtacks. Allow a few inches of overlap at the edges to account for shrinkage when the resin is applies. You can trim the edges later.
3. Mix no more than a pint of fiberglass resin and hardener in the proportions recommended by the manufacturer. Don't mix more than you can brush on in five to 10 minutes to prevent it from hardening in the mixing bucket.
4. Brush resin into the fiberglass cloth till it is thoroughly saturated. Use the edge of the fiberglass spreader tool to work the resin into the fiberglass cloth. When it turns clear, the cloth has fully absorbed the resin. Use the spreader tool to work out any bubbles in the weave and smooth the surface.
5. Repeat till you have covered the entire surface of the fiberglass. Depending on how thick you want the fiberglass, you can lay additional layers over the top of the first one in the same manner. Work quickly so the layers will meld into a single layer of fiberglass. Don't let the resin set between layers.
6. Cure the fiberglass overnight until it is well-hardened. Clean your tools with acetone. Once the fiberglass is set, lift your new fiberglass speaker enclosure off the mold. Pull the plastic from inside.
7. Trim the excess fiberglass from around the edges. Mark and cut out wire passage holes and speaker openings with a saber saw and drill. The fiberglass will cut smoothly with a fine-tooth saw blade. Drill holes to mount the speaker, if desired.
