The next day (August 31), I took the pieces to Tahir, Fiberglass guy for covering the skeletons with fiberglass.
I wanted to reduce the footprint of the piece, so I asked him to cut small angular piece from the base
This is how the final shape of the skeleton looked
The second piece being cut ...
It appeared that the holes needed to be widened by a milimeter or so
We wrapped the piece in flannel cloth ... Ghulam Hussain is holding the piece. We used instant glue, drop by drop, the attach the cloth to the skeleton
You can see the instant glue drops ... as soon as the glue touches the cloth, it burns it due to chemical reaction, making a strong bond
Ramadan Showing its colours on Khokar sahib..!!!
The cloth is covered with fiberglass resin ... we added one more layer of fiber over it. You might recall that while making the subwoofer enclosures, I had 8 layers of fiberglass ... however, in case of tweeters, there is no issue of body flexing, so these two layers were more than sufficient
:D Suleman Bhai .. you are right ... I wanted to finish this project before Ramadan, so that is why you see so much hurry in completion ...
It is very dirty and messy scene while doing the FG fabrication ... I did not want the earlier scene in my house, so I went to Tahir ...
adding the FG layer on top of cloth and brushing with resin
When I did the FG fabrication, I used the appropriate quantity of hardener to the resin, however, Tahir used "enormous" quantity of hardener, so that the material could harden early. He also used lot of cobalt, speeding up the hardening process
Tahir's normal work is confined to make body parts for Ford wagons for which he uses female patterns. However, he kept on mumbling about this piece, which required step-by-step application of layers.
Now the bad part ..
I had stuck the flannel cloth very carefully to the edges of the wooden piece. However, he did not trim the edges carefully, and that formed a "bundle" on the front. This caused a lot of trouble later on, as he had to use enormous amount of putty to level the front side
You can see the imperfections on the front of the pieces ...
Owing to the putty filling on the front, the thin front plate grew to very large thickness. I asked a car painter next door to help, and actually he helped with leveling of the front plate
You see the bottom part in this photo ...