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yea, I hear ya on the foam stuff. but if you are trying to copy a part, and said part is available, it's usually easier and faster to lay some plastic over it and fiberglass it that way. K, so here's the completed shot of my Sub / Spare tire in the spare tire well...
 and here's the raw (VERY raw) sub box. I covered the spare tire well in plastic and made a fiberglass copy of that. then I put plastic inside the spare to to make the other half of my sub 'box'. I fiberglassed em together and came up with a perfect fitting sub 'box'. This is the raw form and was only a week or two old at this stage. total volume is roughly 1.5 cubic feet (sand method)

Petz #3 |
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