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[TheDavel]

Originally Posted by dbTroy

Awesome install.. Nice and clean.

Do you have any pictures from when you built the kick panels? If not, can you talk about how you built them, if they are sealed or open in the back, etc?

No build picks on them but I basically started with a series of templates. I will make an attempt to put what I did into words.

Template
I started my template by tracing the outer diameter of the woofer and tweeter next to each other in a teardrop like Faison on 1/2" MDF. Then I cut the shape out and used a perfect circle jig and router combo to cut the holes for woofer and a hole saw for the tweeter. I then used a rabbit bit to recess the woofer in its template so that it would sit flush when the plexi was sitting on top of it. Once this was up to standard I used that to make several jigs for each sides and for the plexi covers. I then made a frame for the outside of the template which was 1/16 of an inch too big on all sides to accommodate for vinyl and give a nice snug fit. The frame was 1" in depth and I attached 1/4" MDF on the bottom to create a base. A flush cut router bit was my best friend during all of these steps

Prepping the kicks
I used a DA with a 24 grit sanding disc and scuff up the kick panels. I then made a template out of 1/8" MDF that replicated the factory kick panels shape and attached it using screws and fasteners. After taping the floor and putting plastic down I started fiberglassing the base. After glassing the bottoms I trimmed them down a bit... final trimming was done after the templates final resting place was determined.

Framework
I drilled a hole and used a string that I pulled to a spot on my window describe in Rick from rammaudios write up. Once this was achieved I used a lot of CA glue to set things in place.

Glassing
I stretched grill cloth over the kick and CA glued it into place ensuring it was really tight with no wrinkles. I then placed it back into the car and glassed it into place. I put about 5 layers on the kick prior to removing it. Once removed I sanded/grinded it down and Dura glassed it. Lots of sanding later I had some “decent” at best looking kick panels that were ready for vinyl.

Note: I re-enforced the inside with a Dura glass resin mix for added strength. The kicks are also dynamatted and stuffed with poly fill. The were sealed initially but that caused some issues with the plexi, I ended up making a 2.5 inch hole that opened onto the floor.

Hopefully this is a decent write up but It would be easier to do and understand if I had pics that would talk for themselves...

These will be redone either way as they suck.