I took some time this afternoon and reworked my mold and then prepped it for fiberglass. I got a little carried away and didn't snap pictures until I was all done with my Styrofoam mold. Basically I laid down two pieces of 1.5" Styrofoam and sanded the heck out of it to get the shape I wanted. Then I covered the whole structure in aluminum foil which will serve as a quick release of the final shape once I glass it.
I ended my afternoon with laying down my fleece on top of the aluminum foil, on which I will apply the fiberglass resin and ultimately make my door pod.
Again not a great picture but here is the form with fleece glued to it. I will eventually smooth any areas which are not perfect using body filler in the end, but you can sort of see the form coming together.
Finally I leave you with a couple of mockups of speaker setups. I am wanting to get as much bass in the doors as possible so am trying to decide if I want to do a 6.5inch with 4" mid (ala R171) or do a pair of 5 1/4" woofers and move the 4" to the kicks.
I might be able to fit an 8inch, but it would require some additional strengthening of the panel I do not plan to do, plus I have these flush mount rings from MB Quart circa 1998 that if I can find speakers to drop into them will look uniformed.
Above is the 6.5" and 4" mid
This is a pair of 5.25" woofers
This is another idea, that would require some additional molding of my form and I do not think it will look right. To busy for the look I am going for.
Anyway, that is my work for today and other than laying down fiberglass probably all I can do this week.