A co-worker of mine wanted bass in his Honda S2000. Of course, he didn't want to add much weight, or give up any of the limited trunk space. He also didn't want to give up any of the passenger's leg room, so a foot well box wasn't considered. After pulling the trunk trim panels I thought I could fit a woofer enclosure for a single 8" inside the factory "donut" spare tire. The OEM bolt secures everything to the car, and the slight bit of added weight (although high) is over the rear axle, not behind it. When finished he was quite happy with the bass and fully functional trunk.


1.  

I began by masking off the inside of the "donut" with painters tape. I then used some some Super 77 to glue some black trunk liner to the taped surface. The trunk liner was used because I planned on wrapping the enclosure when finished.

2.  

I used another layer of painter's tape over the trunk liner, and glued some aluminum foil over that

3.  

I started laying chopped mat and fiberglass resin in the tire, and another quick test fit of the woofer never hurts.

4.  

I finished 'glassing the tire with more chopped mat and resin. I tried to keep the fiberglass layer between 3/8"- 1/2" thick throughout.

5.  

Three-quarter inch MDF was used for the face of the enclosure, and I offset the woofer to give it as much room as possible. The center of the tire is the shallowest point, and the OEM bolt will secure it to the car.

6.  

I used a grinder to angle the outside edge of the MDF so it would fit close to flush to the edge of the donut. The woofer will protrude into the cabin, so it can be surface mounted.

7.  

I used the OEM bracket to center the mounting hole. The bracket won't be used, but the OEM bolt will secure the donut and woofer enclosure to the vehicle.

8.  

The enclosure is bolted down, and I start to cut the plastic rear parcel tray. I cut a hole large enough for my hand to fit through so I can use a marker to trace the woofer's mounting hole from underneath.

9.  

Here's the parcel tray back out of the car, with the marker outline of where I need to cut.

10.  

Here the tray is still out of the car, and I cut along the mark.

11.  

Here the tray is back in the car, and the hole in the plastic lines up with the woofer's mounting hole. Later I'll have to enlarge the cut out in the plastic so the woofer can mount directly to the enclosure.

12.  

The enclosure is finally removed from the donut, and the tape, trunk liner, etc. is removed.

13.  

Rear of the enclosure.

14.  

I used a bandsaw to trim the excess fiberglass.

15.  

Bandsaw in action.

16.  

Rear of enclosure with tape and foil removed. Remember to scuff the fiberglass so contact cement will adhere.

17.  

D.A.P. contact cement was applied to the enclosure and a piece of black trunk liner.

18.  

Rear of enclosure wrapped in trunk liner. The only reason I wrapped the rear of the enclosure is because I thought raw fiberglass would make plenty of noise against the steel donut when driving.

19.  

Face of enclosure wrapped in trunk liner.

20.  

The enclosure mounted to the car, as seen from the trunk.

21.   

Here you can see the woofer through the rear plastic window. The parcel tray hole was enlarged to the outer radius of the woofer.

22.  

Here the woofer's optional grill is mounted.

23.  

Trunk with all trim panels in place.

24.  

Woofer, viewed from drivers' seat.