Next up, I needed to figure out a way to take advantage of all this extra airspace. What I settled on was card board templates, that I would use to form a fiberglass mold. In using cardboard, I ensured that I wasn't butting up my fiberglass mold right against other panels, which then allows me the ability to insulate the enclosure with some foam... i'll probably use some extra 1/8" ccf I have, that way if the box ever does come into contact with another panel, resonances will not be something I'll be worried about...
First, the templates of the exterior wall:
and then taped in:
then I started applying cardboard walls, with tape to make the form for my mold:
before pulling them out, I used a sharpie on the outside of the boxes to determine where i should cut the molds to bring them flush to the interior metal parts. once this was done, I carefully pulled them out and reinforced them from the outside:
