Bronco Subwoofer Enclosure

Very crude enclosure I've designed for the 6th gen Broncos to fit a Hifonics BXS10D4 which has a mounting depth just shy of 3 inches and is relatively inexpensive. This was modeled using my 2022 2-door full size Bronco so I can't make any claims on fitment for other models/trims. 

Recommend printing in PETG or better. I used PCTG which has slightly better heat resistance than PETG though it was a bear to tweak for proper printing. Using a 0.6mm nozzle at a 0.4 layer height I did 2 perimeters and 2 top layers for the enclosure at 10% infill. The air chamber was printed at 0.4mm layer height as well with 4 perimeters and 4 top layers. The chamber is designed as a solid block to allow for infill which can be used as internal bracing, which means you'll need to include custom layer height modifiers for 0 top layers at layer height ~229mm. I used 1% grid infill aligned perpendicular to the exterior walls. Brackets were printed solid and on their sides for maximum strength. Be sure to block supports on the top bracket's mounting hole when printing the enclosure to keep it open and available for receiving a screw.

For assembly, I used M4 threaded inserts in the air chamber along with hot glue to bond and seal it to the enclosure. the enclosure is bolted through its back to a coinciding hole on the Bronco chassis. The top bracket uses a screw + hot glue to attach to the enclosure. The lower bracket is installed onto an unused section of M6 thread with a washer + nut and is attached to the enclosure last through a hole in the speaker's mounting ring. I used random appropriately-sized hardware I had laying around to bolt on to the Bronco.

This setup hits very well despite being undersized for the sub's specs (volume is probably ~0.22 cu ft) on my system using the Hifonics sub and a JBL Club 5501. There is a mild rattle which I believe is from a piece of infill that didn't print properly on the enclosure (100% solid would've been ideal) though this rattle is very mild and hard to notice when the truck is running - doubly so if the climate control is on.

Ideally I'd add a threaded insert to the far end of the air chamber to allow it to be bolted down to the Bronco as well, so I've included a hole for a threaded insert in this version, though I don't actually have this setup in use yet. It would also be nice to add another mounting bracket to the top rear of the enclosure, though I don't have any provisions for this right now. As it stands, the mounts in this version are fairly solid and the enclosure itself does not rattle against the body and has very little flex, though time will tell how this holds up. I used CLD and decoupling foam (technically just the soft side of a velcro roll)on the enclosure and air chamber to help prevent any unwanted knocking. Will probably work on a speaker grille down the road after I've had this setup running well for a while.