Speaker enclosures are not very hard to make. In fact, it's rather fun to see something that you drew a sketch of materialize. I believe Squid makes his boxes out of 100% fiberglass, no MDF. They look really nice too! This being my first box to make I took the easy route and used a wood frame.
Basically, I made a frame and stretched fleece fabric over it to create the shape. I then coated the fleece with polyester resin and let it harden. I applied roughly 5-6 coats of resin to the outside of the box. I also applied 2-3 coats of resin on the inside of the box.
I then applied one coat of fiberglass filler to the entire outside of the box. Fiberglass filler is a lot like bondo, but a little more dense. This step adds some strength to the box and helps to fill in the little valleys in the resin. Currently, I am in the process of sanding the box to get it ready for paint.
So far I have roughly $70 into this box. It's been a ton of fun so far. I can't wait to get it finished. I'll post some more pics when it's done.
(Message edited by nauty on October 07, 2005)