Gather your materials, make speaker rings for the speakers that you are putting in the kick panels by mounting the grill on a piece of MDF and use you router to cut them to size.

Step 2

Remove your factory kick panel. 

Pull the weatherstrip off in the area near the kick panel. 

Pull the carpet back and secure it so it doesn’t get ruined.

Step 3

Cover the area with aluminum foil and tape it up to hold it in place.

Remove the clips from your factory kick panels and carefully poke them through the aluminum foil.

Hold the factory kick panel in place over the foil and trace the edge with a Sharpie

Cover the rest of your work area with a drop cloth!

Step 4

Rip your fiberglass mat into small manageable pieces (1-2").

Mix up a small batch of resin according to manufacturer’s instructions.

Soak your fiberglass mat one piece at a time and start laying them over the foil (make sure to push some mat into the clips that you poke through the foil). 

Lay 5-6 layers of mat down and be sure to push as many air bubbles as possible to help make your finished piece stronger.

Step 5

Now would be a great time to go eat lunch and watch a movie. After the fiberglass has dried completely and cooled down, trace your lines from the foil onto the fiberglass.

Carefully remove the fiberglass base from your vehicle, make sure you take care not to ruin the clips as you pop them out.

Step 6

Trim the fiberglass back on the piece that you just made to 1/4" inside the line.

Step 7

Now place the speaker rings onto the fiberglass piece using dowels and super glue to get the angle you want (make sure you have proper clearance for the speaker you are putting in).

Use super glue, dowels, and MDF to create the rest of the skeleton to get the shape you want.

Make sure you cut all the pieces for your skeleton for both sides before you attach any of them to the fiberglass so the 2 panels will match.

Step 8

Use super glue to secure your fleece to the speaker ring. 

Stretch and glue the fabric to the back side of the fiberglass all the way around (Pull it tight so it doesn’t sag).

Mix more resin and pour it onto the fleece, making sure to let it soak through the fleece (spread it on with a bondo spreader to make this easier).

Step 9

Apply 3 layers of resin soaked mat over the entire fleece covered area.

Add some shredded mat to an extra batch of the resin and pour it inside the panel, then push it into the area where the fleece meets the fiberglass to help with strength.

Step 10

Your kick panel is now ready for the finish work.

Remove any excess material from the back side of the panel using your router and a flush trim bit.

If you are carpeting it sand it smooth with 40 grit, carpet it, install it and enjoy!

If you are painting it sand it smooth with 40, then apply body filler and sand with 80, then more body filler and sand with 400. Primer and paint!