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A large round hole (for the sub) was cut into the front cap and it was fastened together with carpenter's glue and wood screws. Next comes the layers of fiberglass. The resin was mixed up with the hardener and pieces of glass matting were soaked in it and stuck to the wood and cardboard assembly. Once it had hardened, it was dragged outside to sand smooth. |
After this first wave of sanding (which took forever with that orbital sander), I decided the corners were too sharp. Also, the shape was not quite right with the tube bulging too much. So I dragged it back inside and gave it a second, heavier coat of glass.
Now it was thick enough that I could easily round out the corners. However, after the last ordeal with the orbital sander, this time I gave my brother-in-law (a bodyman) a call to see if he had any better and faster techniques. Instead of advice, what I got was a bodyman (for the low, low cost of a few beers!)
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