Long weekend means work can get done! Time to tackle those door speakers.
Off with the "skin":
Here is the replacement tweeter next to the factory one:
Lots of little parts to make up the tweeter assembly:
Obviously this isn't going to fit without a fight. So hafta drill the hole in the sail a little larger:
Using the dremel and my knife, I smooth out and finish the mount. Got pretty much a perfect fit:
Next comes the woofer. Again, here is the factory 6x9 with its replacements:
Before trying to fit these I've got to soundproof the inside of the door. What a pain this is - glad I've only got to do it once more!
Obviously, the 6.5" isn't going to fit in the 6x9's hole so I make an MDF mount for it:
I painted it black so it won't be noticable through the grill:
I also mounted the mid bass with another MDF mount. First I cut a hole in the door skin where I want the grill to go:
Now that I can see where the grill is, I cut the mounting hole for the speaker:
A test fit shows the foam behind the door skin (I assume it is support for the arm rest) is holding the assembly too far out:
Out with a fillet knife and trim that down some. I also now used RTV to hold the foam securely to the panel:
I fished three runs of 14/2 speaker wire into the door. Man, that wasn't easy!
The rubber tube that the wires run through into the door is only about an inch in diameter and there is pretty much an inch of wires already in there!
Next is a second layer of soundproofing this time using the thinner foil backed variety. This type is sooooooo much easier to work with. The inside took about three hours, this took less than one:
I put some black duct seal around the hole where the woofer will fit:
And in it goes:
Next, the mid bass:
Any wiring that looked less than secure was wrapped with fuzzy velcro to ensure no rattles:
And here is the end result:
Now to get that skin back on.
I have to trim the mounting flange away from the grill for the mid bass:
It is clamped in place:
And glued to the panel using JB Weld:
Oops - off with this thing!
Here is the final re-assembly:
Of course, I had to rebadge the factory grill:
Next is to run those cables to the amp rack and start over again!
With luck, by this time next week I'll be doing level settings
.