d16rice

Step-by-step instructions for modifying EK (EJ) front door panels for 6.5" speakers

Tools/supplies needed:
- Six small screws (to hold the baffle in place)
- Eight larger screws (to hold the speaker in place)
- Undercoating (to seal in the baffle)
- Painters tape (optional, but helpful)
- Bright color permanent marker
- Dremell with cutting discs
- Baffles (from PepBoys)

I know some 6.5" speakers fit without modification, in which case you don't have to read this, but if your speakers don't fit stock baffles, continue on reading.

Firs, take the door panels off.
The previous owner already cut the back of the baffle off, which wasn't the best thing to do, because if it were to rains, water would drip on the speakers.



Cut the whole baffle out, not just the back, got to go all the way to the flat surface.



Cut off the three speaker mounting brackets



Since the hole is an oval, you’ll have to make it rounder to accommodate the new baffle



Make it as round as possible.



Make sure the new baffle fits



Cut out the lower part of the new baffle as shown. This way you’ll be able to enjoy deep bass, while your speaker is still protected from the rain. Due to the cut, the baffle will loose some of it’s rigidity, but we will address this later.



Using three smaller screws (per panel), mount the new baffle.



Cover up the hole from the inside of the baffle (blue painters tape works nicely).



Spray the inside of the panel with undercoating. This will make the baffle sturdier and it won’t vibrate as much. Don't forget to remove the painters tape before installing the speaker.



Install the aftermarket 6.5” speakers.



Clean off the door frame and apple tape (blue painters tape if you have it). This will prevent paint from chipping and gives you a nice surface to draw on. Mark off the speaker opening edges and then another half an inch radius wider circle for the new opening.



Cut out the new speaker opening



After puting the panel back on the door, install the speaker grill


__P.S._____________
I'll probably add more pictures on hooking up the speaker and what not, but for now, this is all.


Modified by d16rice at 5:42 PM 12/20/2005

camo hatch

nice job. ive had to do this several times at work when working on EKs

aZnjCC

good ****! are those references? I was gonna use a plastic baffle to mount mine as well, but realized that i would have to cut away the metal. I got lazy and scrapped that idea and just mounted em to the regular panel. I did have to cut away most of the plastic, and used dynamat to ensure a tight seal.

d16rice

Yah, the speakers are Infinity Reference series 6000cs.
If anyone's wondering, I got the baffles at PepBoys for around $10 (pair),
and the undercoating at Autozone for $5 (DupliColor).

I'm using Dynamat, too.
I alerady put the inner layer on the door skin,
and I'm wondering if I should put an outer layer between the frame and the panel.