A different kind of box

[easelman]

I decided I wanted to add an amplifier and dynamat (sound deadening) my fj. I was looking for a place to place my zapco 2100 and decided to put it in the back left panel.

One problem - It didn't fit

So I decided to refabricate the left rear panel to hide the amp and store some of my supplies. If your not familiar with my rig, my hi-lift jack hangs on the inside of my back door with the jack "head" and stand to be taken and put into my rear left panel for a clean look.

Here is the beginning of the build.

pic 1, take off panel, screw in piece of wood to mount the amp. The wood is mounted on the tie down screws that were removed. Another piece of wood will be screwed to the sheetmetal.

pic 2. The plastic panel is partially cut out but the outside edge kept the same to fit back perfectly.

pic 3. wood panel mounted up. Taped up so I could fiberglass them together behind the wood.

pic 4. After the fiberglass, bondo the front.

pic 5. First layer of fiberglass (before the bondo was put on)

It has been bondoed, and sanded and more pics to come and how I will get access behind the panel.

[easelman]

Although no one cares , ill post up my progress and finished product soon.

Maybe its the camera phone pics or maybe this is more of a 'different' type of mod than the normal expedition style mod.

pic 1 - Bondoed and sanded the box to give it a natural look. You can see the access door I made.

Pic 2 - Fully primed and done

Pic 3 - close-up

Pic 4 - finished product in the garage. The shiny box is an aluminum frame that protects the panel when I pull objects in or out.

Pic -5 I appologize but this is at night but its in the car.

The access panel is a strait pull out door.

I used all car paints and SEM flexible satin black spray paint and texture.

This holds my amplifier, hi-lift base: Hi-Lift Off-Road Base (ORB) - alleviate jack sinkage on soft ground | Hi Lift Jack Company , my hi-lift jack head and handtools.

[yanos]

Nice Work. How's the fit?

[Ravens_Edge]

looking good

[easelman]

Since I cut out the original rear panel it fits perfectly(see pic 2 of the original post). It doesn't have the same flex to get it on and off but it works. I also had to detach it from the front black panel next to the passenger side.

I test fit it last night and it fits great but I still haven't totally put my car back together. I also dynamatted and wired my amp and took everything out.

This was my first ever fiberglass project and I probably spend about 10 hours working on it and it cost about 150 bucks in supplies. probably about 25 total in wood and fiberglass but then the rest in metal, special automotive flexible paints and textures to match the original car.

I'll get some daylight photos up, I just finished last night and test fitted it into the car.

[jeshua]

Hard to tell from the pics whats going on but it looks like you did a good job on teh molding and fiberglass part.


can you get some better pics up?

[easelman]

I'll get them up today with the sun and good lighting. Hopefully I can get the texture and a clear shot of how it fits.

[easelman]

Ok here are some Daytime photos. I don't have the rest of the panels in yet but I think you can see how it fits. Its the same width as the normal panel except it extends up and is flush with the back of the seat.

[Wyoming Cruiser]

Nice work...That is a talent

[nevadaesh]

Wow, that's ambitious to say the least. Very nice work.