How to make a fiberglass splice box tray

A fiberglass splice box can be made by constructing a mold or frame, layering fiberglass sheets with resin, and finishing it to house fiber optic splice trays securely.

Materials and Tools Needed

• Fiberglass cloth or mat and resin (polyester or epoxy)
• MDF or poster board for mold/frame
• Hot glue, super glue, masking tape, and tin foil for shaping and protection
• Sandpaper, scissors, and protective gloves
• Fiber splice trays and splice protection sleeves for fiber management
• Fiber tools: stripper, cleaver, mechanical splice connectors, lint-free wipes, and isopropyl alcohol

Step 1: Design and Mold Preparation

1. Draw the base and dimensions of your splice box according to the number of fibers and trays you plan to install.
2. Use poster board or MDF strips to create a mold or frame for the box. Contour edges carefully to match the desired shape .
3. Mask areas where you don't want fiberglass to stick using plastic sheets or tin foil .

Step 2: Building the Fiberglass Structure

1. Cut fiberglass cloth to fit the mold.
2. Mix the resin and hardener according to manufacturer instructions.
3. Apply resin to the mold and lay the fiberglass cloth over it, ensuring no air bubbles. Repeat for 2–3 layers for strength .
4. Allow the fiberglass to cure fully before removing it from the mold.

Step 3: Finishing the Box

1. Trim excess fiberglass and sand edges smooth.
2. Optionally, apply a gel coat or paint for durability and aesthetics.
3. Drill or cut openings for cable entry and exit, ensuring proper bend radius for fibers .

Step 4: Installing Fiber Splice Trays

1. Place fiber splice trays inside the box, securing them with screws or adhesive.
2. Strip, clean, and cleave fiber ends before splicing .
3. Perform mechanical or fusion splicing as required, then protect splices with sleeves.
4. Organize fibers neatly in the tray, maintaining bend radius and labeling for easy identification .

Step 5: Testing and Final Assembly

1. Test all spliced fibers using an OTDR or power meter to ensure signal integrity .
2. Close the box securely, ensuring it is dust- and moisture-resistant.

Safety Precautions

• Always wear gloves, safety glasses, and a respirator when working with fiberglass and resin .
• Handle fiber optic strands carefully; they are sharp and can cause injury .
• Dispose of fiber scraps and resin waste properly . By following these steps, you can create a custom fiberglass splice box that protects fiber optic splices, allows organized cable management, and ensures long-term reliability.