Hey guys, I needed to replace the warped, rotten door cards. Here is what I did, perhaps it will help someone.
It started with the need to replace a blown door speaker. This lead to the discovery that some genius glued the door car to the door after recovering the cloth section of the door. I wasn't going to be the DPO on this one so I opted to take my time and do the best job I could.
I order some 1/8" pvc panels on Amazon and some replacement stock-style door trim clips from ebay. I also order some speakers from Crutchfield. One thing I wanted to try was placing some tweeters high on the door. It was important to me to keep the stock look so the tweeters fire through the cloth. Yeah, they loose a little high-end, but who are we kidding it's a 60 with a header!
Anyway, hope these pics help tell the story.
~ Carl
Crappy old card
decent front
Two sheets of PVC taped together and one of the stock card SCREWED onto the PVC to keep everything from shifting.
Using machinists transfer punches to mark the holes
After drilling all the holes on the drill press and cutting the plastic on the bandsaw. This stuff is soft and could have been done with a jig saw and and hand drill.
Next, after separating the two halves I cut the slots with a jigsaw. I also glued the tweeters in with some silicone.
Here is the back after the cloth was reattached. Hard to see, but I attached the stock metal part at the top with some short screws and square nuts. Between that and the map pockets the cloth was pretty tight. I only used the duct tape to keep the ends inside. Yeah, I know, duct tape is lame.
Here is the front. The tweeter is right above and to the right of the window crank hole.
And here is the finished door in place.
It started with the need to replace a blown door speaker. This lead to the discovery that some genius glued the door car to the door after recovering the cloth section of the door. I wasn't going to be the DPO on this one so I opted to take my time and do the best job I could.
I order some 1/8" pvc panels on Amazon and some replacement stock-style door trim clips from ebay. I also order some speakers from Crutchfield. One thing I wanted to try was placing some tweeters high on the door. It was important to me to keep the stock look so the tweeters fire through the cloth. Yeah, they loose a little high-end, but who are we kidding it's a 60 with a header!
Anyway, hope these pics help tell the story.
~ Carl
Crappy old card
decent front
Two sheets of PVC taped together and one of the stock card SCREWED onto the PVC to keep everything from shifting.
Using machinists transfer punches to mark the holes
After drilling all the holes on the drill press and cutting the plastic on the bandsaw. This stuff is soft and could have been done with a jig saw and and hand drill.
Next, after separating the two halves I cut the slots with a jigsaw. I also glued the tweeters in with some silicone.
Here is the back after the cloth was reattached. Hard to see, but I attached the stock metal part at the top with some short screws and square nuts. Between that and the map pockets the cloth was pretty tight. I only used the duct tape to keep the ends inside. Yeah, I know, duct tape is lame.
Here is the front. The tweeter is right above and to the right of the window crank hole.
And here is the finished door in place.
