Part Contents: Hi! I’m Zach Telford, and you’ve downloaded my subwoofer box plans for 1 and 2nd Gen. Ford Explorers and Mercury Mountaineers. As a forewarning, this design has only been tested on a 2nd Gen. Ford Explorer XLT. Ok, now a little bit of background. I’m a 20-yr-old Russian translator for the military. My dad is a contractor, but I grew up with my mom. I spent my summers with dad and learned a little bit about woodworking, but it was mainly framing. I’m really good with math, but this box really only required some basic geometry (Pythagorean and SOHCAHTOA).
So basically, I’m not all that experienced with woodworking, but I am cheap. I had no desire to spend $200 on a stupid box. Wanting to stick it to the man, I decided to write this comprehensive guide to building a custom box for your Ford Explorer (or variant).
Specifics
There are a few things that were specific to my box design that could be changed. For instance, I used an angular cut on the bottom to clear the wheel well. If you’re skilled enough, you can bend it around, use fiberglass, or be creative and do something wackier to gain volume. Angular cuts worked for me. The other, and more important difference is the depth of the box. I used 5/8” particle board all around, and then used two ½” sheets of MDF stuck together for the face. This created a 1” thick face and very little depth. As a result, my sub barely fit. I used an Audiobahn ALUM10Q. This box was designed around that sub. I cannot guarantee any other sub will fit, so builder beware!!

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