This month we continue with the final steps of the cosmetic panel that will cover and finish the kick panel enclosure we started in the JulY issue. Although sound is very important when it comes to an installation, it's equally important to have the right look. We'll go over some basic techniques to help you achieve both great audio and aesthetics!
 1. The cosmetic panel will...  1. The cosmetic panel will be made primarily of fiberglass, so the first order of business is to mask off the entire kick panel and surrounding area with the kick panel enclosure still in place. |  2. Using 3M Super 77 spray...  2. Using 3M Super 77 spray adhesive to hold it in place, apply aluminum foil over the masking tape. Use a new body filler spreader to smooth the foil out as much as possible. Once finished, apply mold release agent to the surface of the aluminum foil. |  3. This next section requires...  3. This next section requires 1.5 ounce fiberglass mat and resin. Tear the mat into roughly 3" by 3" pieces and apply evenly over the kick panel area using resin. Apply four layers of fiberglass mat for best results. To prevent warping, allow the fiberglass to fully cure before removing it. |
 4. Using a marker, create...  4. Using a marker, create an outline of the desired shape of the kick panel cover. |  5. Remove the kick panel cover...  5. Remove the kick panel cover from the vehicle. Using an air saw, cut along the outline you created. |  6. Because the kick panel...  6. Because the kick panel enclosure has a plateau at the top, so does our trim panel. This shape would be nearly impossible to upholster without stitching. Since we'll be upholstering ourselves, use a small amount of two-part urethane foam to blend the area to keep the kick panel cover fairly light. Finish by applying two layers of fiberglass mat over the foam surface. |
 7. Using an angle grinder...  7. Using an angle grinder with a 24-grit roloc disc, knock down all the high points and grind the entire surface until it's relatively even. |  8. For this next step I like...  8. For this next step I like to use Rage Gold body filler, but any body filler will do. Mix an appropriate amount of body filler with the hardener according to the directions and spread it evenly over the entire surface. Remember to be generous with the application. If done correctly, you should only have to apply this once. Use 40-grit sandpaper to smooth out the edges. |  9. Now, using 36-grit sandpaper,...  9. Now, using 36-grit sandpaper, hand sand the surface until the desired shape is acquired. |
 10. Once the final shape is...  10. Once the final shape is achieved, mask off the entire kick panel cover with two layers of masking tape. Sketch out the shape of what will eventually be the fiberglass insert trim for the speaker and tweeter. |  11. Using a razor, follow...  11. Using a razor, follow the outline you sketched. Once cut, remove the excess tape to reveal the shape. |  12. Spray glue over the entire...  12. Spray glue over the entire kick panel cover with the masking tape in place. Again, apply aluminum foil and smooth with a body filler spreader. Notice how I took the edge of the spreader and pressed it against the tape edge underneath the foil. This will allow the masking tape edge to transfer to the fiberglass insert. |