[jimmydean]

Fiberglass is messy.

Here is how I built mine, you can do it literally a dozen or more ways.

1. I used cardboard to make a template of my kick panel.
2. Transfered the shape to some thin (3/16?) mdf
3. I wanted the speaker to fit in the hole where the vent was to keep it out of the way, so I cut out the hole for the vent, too.

4. To protect the back side of the speaker, I used the vent I took out to make a pocket mold

5. Make a template ring to mount the speaker(s) to
6. Figure out where you want the speaker to fit in the panel (high, low, in the middle, flush, aimed, whatever)
7. Mount the ring to the panel in the position you want (I use dowels or scrap wood and hot glue to hold it in place)
8. Using some fleece, stretch it over the panel and glue it to the panels back side (hot glue works well)
9. Mix up some fiberglass resin and brush it until soaked into the fleece
10. Using fiberglass mat/cloth, drap it over the fleece and brush with resin
11. Repeat as needed (I like to do at least 3-4 layers of cloth)
12. Once the glass has cured, you can use regular body filler to smooth the surface of the panel if it needs it
13. Once you are happy with the shape, cover with vinyl, carpet, paint, leather, monkey fur, shag, whatever.

For mine, I used a small amount of padding and vinyl that matches my seats and doors.

There are a lot of youtube videos to show it in action.