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I considered making my "mold" out of cardboard so I could change the tweeter from firing across the dash. I wanted my tweeters directed at the seats rather than the dash. I liked how the pod accomplished exactly where I wanted the tweeter to be directed.
Pete-
I had zero experience when I started making subwoofer enclosures for underneath my vert rear deck. I got on some audio forums and saw some walkthroughs of how people had used spare tire areas as subwoofer enclosures. I used that as a basis for what I did.
I used the well from the transmission hump as my enclosure. I laid thick trashbags in the well and used tape on the underside of them to get them to fit the contour of the well. I used packing peanuts to measure the inner volume. I can explain how, but this whole sub box thing is already a little off topic. Getting back to the fiberglass.....I laid a couple layers of fiberglass. After a couple layers I then had a wooden rectangular frame for the top of the box to screw down onto. I laid that on the fiberglass covered trashbags with some cardboard to fill in the gaps between the frame and the bag. From there I put a few more coats of fiberglass on with some woven mats cut into strips. Pretty much I did like papermache and encapsulated the wooden frame into enclosure.
Once I had a strong enough "box" I could pull the whole thing out of the car so that I removed any risk of spilling liquid fiberglass and ruining the interior of the car. I sanded off the trash bag cause it was no longer needed. From there I added layers on the inside of the enclosure until it was strong enough. Cut the lid/top sink some screws through it into the wooden frame and waaa laaa a subbox that uses up previously unused space.
Point of all that is that using fiberglass is really pretty simple once you get started doing it. Like TTT explained about being safe with it and you're good to go. One thing I don't remember seeing in TTT post..which it very well might be there. Use a filter when you're using the resin. My family does alot of construction so I had access to double filter breathers for painting.
One thing I like about my idea of building a cardboard mold is that it's risk free. You're not running the risk of accidentally getting fiberglass on interior parts. If you fuck up the work all your out is a cardboard box you made. Once the enclosure is made you can cut and sand it down to create a flush mount up against the triangle mold as well as the door panel.
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