Spruced-Up Stealth Box- A TO Z

Use an air saw to cut the holes in the fiberglass insert.

Mount the speaker in place and use a CA glue to bond the MDF ring to the fiberglass.

To ensure the rings do not move during the foaming process, it's a good idea to apply Duraglas around the edges of the ring. This is only a temporary bond. We will later create a permanent bond when we fiberglass the surface of the foam. Notice I've masked off the MDF ring to protect the cone of the speaker from getting damaged.

We will use two-part urethane foam to create shape on the surface of the insert.

I've created a poster board wall around the insert with masking tape. This poster board barrier will allow the foam to rise without pouring out all over the place.

To help speed up the curing process for the foam, puncture a hole in the foam using a blow tip and lightly blow air. This will help cure the core of the foam quicker, allowing you to grind and shape sooner.

Use an angle grinder and an air saw. Notice I have a large metal saw blade in place of a normal air saw blade. This works great to carve off the excess foam.

Hand sand the surface of the foam with 40-grit sandpaper. Here is a finished shot of the foam after it's shaped. This alternative way of creating shape is a better process than using a gallon or two of body filler to achieve the same look.

Mask off the enclosure and bolt the insert in place. Apply four to five layers of 1.5-oz. fiberglass mat on top of the foam. Notice I've masked off the center of the MDF ring to prevent resin from reaching unwanted areas. Also notice I've bolted the insert in place during the fiberglass process to ensure the insert does not warp out of shape.