After removing the Bose wave, I closed the holes in the privacy cover. There are plastic frames in the privacy cover around the holes where the Bose wave speaker covers come through. I pulled these 2 frames out of the privacy cover, fiber glassed over them, and then covered them with black felt.

For the fiber glassing I drilled small holes in the upper surface of the frames to hopefully let some resin penetrate in there to help the strength of the bond, but this is probably not necessary. I put out some waxed paper and prepped a piece of basic fiberglass cloth with resin on the waxed paper and just laid the top side of the cover on this. After drying, cut off excess fiberglass and I used a grinder to smooth out the curves at the four corners. For the best result, you could smooth out the top of the fiberglass surface with Bondo filler but I didn’t and I still like the result. After covering with felt the unevenness of the fiberglass isn’t that noticeable.

I covered these with black felt using contact cement. I’m sure a lot of other adhesives would work fine also. I applied to the felt and top fiber glassed surface as directed and just laid the fiberglassed frame over onto the felt. Trim after drying to leave just enough material to turn under all the way around. Cut Vs in the fabric at places around the corners so the fabric won’t bunch on the underside. Apply the adhesive and turn the fabric under to bond.

I sanded the fiberglass to take the slickness out to help the adhesive bond. I also sanded the underside of the fiberglass and painted it black, since I didn’t cover the underside with the felt.

 

Very smart

 

Thanks, it was the easiest solution I could think of that I thought would be acceptable and it came out better than I expected.

You could strip all the felt off, fiberglass the holes and then recover for a completely stock non-Bose look but I wasn't sure I could get the fabric to stay down given the curves in the privacy cover. I wonder if a mold was used in bonding the fabric when the privacy covers were originally made.

 

You performed a job that is par oem looking. Good job

 

Looks great

 

So these are fiberglassed in to make one solid piece? Interesting in making and selling any?

I have to agree with rocketeerbandit. This looks like some sort of OEM cover option for models which did not have BOSE. I like it!

 

Why not use velcro to attach to the bose cover?

 

subtle and clean. well done.

 

Thanks for the comments, guys.

You could do something with velcro. I think you would still need some kind of backing for the felt going over the holes. Could make a backing a bit larger than the holes, cover that, and velcro it around the edges of the holes.

Using the frames that are already there gives you a method of attachment, since the frames are made to snap into place.

 

I don't have any way to make any, since I used the frames that are already around the holes in the privacy cover. I laid the fiberglass onto the oe frames. As long as you have your 2 frames, it's not difficult.