So I finished up an installation on new door speakers. As background on this, on a trip earlier this year one of my rear quarter panel 6x9 speakers was decapitated when a friend was shoving stuff into the back of my truck. So I decided to move the rear speakers from the quarter panels to the rear doors. At the same time I replaced my front door speakers. I used Polk audio db650 speakers, on sale from Crutchfield, because apparently they are old stock (Polk now offers the db651). The db650's have a mounting depth of 2" (top) and 2 5/16" (bottom)--I'm not sure why the two different dimensions. With the installation described below, the windows do not hit the speakers.
Front doors: In order to switch from a three screw mount (the old speakers) to a four screw mount, I made a mounting ring out of 1/2" plywood. It fit into the original cutout/depression for the front door speaker and I used the OEM screws and plastic nuts to attach the ring to the door. I then used the four screws that came with the speaker to attach the speaker to the ring. It was pretty straight forward.
Rear doors: There is a cut out in the inner door sheet metal. The ash tray sits in the cut out, and I think it's the cut out to remove the window regulator. At the bottom of the cut out are two metal tabs with holes. I made a 1/4 plywood insert that fit into this cut out and held it in place using U nuts on the tabs and counter sunk screws. The plywood insert then had a hole drilled in it for the speaker. I positioned the speaker in the lower front corner, below the window crank. I had to lose the ash tray, though. To get the speaker wires into the doors, I brought the wires up the B pillar and drilled 1/2" holes, one in the B pillar (opposite the door catch) and one in the door. I used 1/2"OD 3/8"ID grommets, then using a short piece of 3/8" ID plastic tubing, I made waterproof (hopefully) wire-way. I threaded the wires inside the plastic tube.
Quarter Panel Trim: To replace the quarter panel trim, I made new pieces from vinyl rubber diamond tread laminated on top of ABS plastic. By making a laminate, I was able to use the OEM fasteners for the panel trim.
Front doors: In order to switch from a three screw mount (the old speakers) to a four screw mount, I made a mounting ring out of 1/2" plywood. It fit into the original cutout/depression for the front door speaker and I used the OEM screws and plastic nuts to attach the ring to the door. I then used the four screws that came with the speaker to attach the speaker to the ring. It was pretty straight forward.
Rear doors: There is a cut out in the inner door sheet metal. The ash tray sits in the cut out, and I think it's the cut out to remove the window regulator. At the bottom of the cut out are two metal tabs with holes. I made a 1/4 plywood insert that fit into this cut out and held it in place using U nuts on the tabs and counter sunk screws. The plywood insert then had a hole drilled in it for the speaker. I positioned the speaker in the lower front corner, below the window crank. I had to lose the ash tray, though. To get the speaker wires into the doors, I brought the wires up the B pillar and drilled 1/2" holes, one in the B pillar (opposite the door catch) and one in the door. I used 1/2"OD 3/8"ID grommets, then using a short piece of 3/8" ID plastic tubing, I made waterproof (hopefully) wire-way. I threaded the wires inside the plastic tube.
Quarter Panel Trim: To replace the quarter panel trim, I made new pieces from vinyl rubber diamond tread laminated on top of ABS plastic. By making a laminate, I was able to use the OEM fasteners for the panel trim.
