Outsmarted myself -- how should I cover/upholster this piece ...

No need to sew. Vinyl or felt the large area. Relief cuts can follow into the complex curved area. Vinyl or felt the lip of the pass through (that is in the same plane as the large area.

Now for the complex curved area. Cut a pattern that can by laid into that area. It will take some work to get the right shape. Once the right shape, transfer the shape to some thin foam (headliner foam comes to mind). Cut the foam and then lay vinyl or felt over that and tuck the edges of the vinyl/felt under the foam. Then glue the vinyl/felt + foam into the complex curved area.

You could use the foam as backing for the large area too. The idea behind the foam is that it should be able to hide imperfections and any over lapped areas that result from the relief cuts or from tucking under.

There will be a seam between the complex area and the larger area and also the lip of the pass through, but it should look good if done well.

Or undo the vinyl/felt on the subwoofer and use bedliner on all the parts .

Source: http://www.diymobileaudio.com/forum/fabrication-tools-tricks-trade/140210-outsmarted-myself-how-should-i-cover-upholster-piece.html

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