Doors are ready for some speaker pods

[Rell]

Ahh okay,

lets talk tools, what do you have or have experience with?

Router?

Circle jig?

Router table?

Jigsaw?

Dremel?

Table saw?

Air compressor?

Personally I suggest you put your door panels back together and put them back on the car. Don't ruin them. Try and find an extra set of doors and mess with those. If you dont have much experience in doing something like this it could turn into an disaster quickly. Then you will end up needing to find another set of doors that hopefully match your car or end up trying to dye the plastic so it will match.

I would vote for making the door all one. Not the door then a speaker pod that attaches. Most pods need the door to be hacked up in the back side anyways making the door usless if you ever decided to remove the pod for whatever reason. Might as well blend it all together to make it one solid door.

Get some speaker rings made for the speaker and tweeter first (go with flush mount speaker rings for the 8in speaker, looks cleaner IMO partsexpress has 8in 2 piece grills that work great with those speakers). Again if you have a router/circle jig etc for the speaker rings it will make the work all look clean. Everything must be symetrical. Once you have rings created you can get an idea of how much room you have to play with and what may or may not need further hacking on the original door.

Just an example (there are many ways to go about this, this is just an idea being tossed into the pot, run with it or take it and modify the example to suit your needs)

After laying down the rings and getting an idea of what you can work with. Create a wood ring that the speaker rings would fit into.

Again if you have a router and router table you only need one to be perfect, then copy it with flush trim bit on the router table. Perfect, now two of exact same pieces.

Position the speaker rings onto this piece, and glue them in place.

Place the ring onto the door panel and outline it out onto the door. Cut the inside of the out line out so that you can take the wood ring and have it fit snug into the hole.

Next, grind the plastic up with air die grinder and roloc discs, lowest grit you can find. Or hand sand the cut out area of the door front side and back side with the lowest grit of sand paper you can get.

Clean and prep the plastic, place the whole wood rings/speaker rings into the hole of the door. Epoxy it into place.

http://www.urethanesupply.com/Flex-Filler-1/Flex-Filler-Cartridge-Kit/

Purchase all the suggested plastic prep cleaners.

Epoxy it into place from front side and back side.

A few hidden screws wouldn't hurt at all either, screw through the plastic and into the wood frame.

Once that is done, all of this is now bonded to the door.

From here use a small amount of fabric and glue to the rings, then stretch out the fabric to around the edge of the wood frame you epoxy into place. Make sure the fabric that is being glued to the any plastic on the door is nice and grinded up from sand paper..Soak fabric with resin to create the shell. Apply one layer of chop mat. Grind/sand the areas again where any fabric/chop mat meets with the plastic on the door. Clean and prep the area where fiberglass meets plastic after sanding. Then apply more of the epoxy, NOT the entire piece just where glass meets plastic. Lightly scuff up the epoxy after it has cured. Then apply the rest of the chop mat to the door. DO NOT exceed the chop mat past the epoxy you spreaded on the door. Aftter enough layers of chop mat have been laid down to make it all nice and solid grind/sand everything again. After that last layer of glass has been grinded I would add just a little more epoxy from the glass out to any plactic (to any plastic tha has been rough sanded and prepped). You shouldn't have any issue with the fiberglass releasing from the plastic for a LONG time because of the epoxy.

Body filler..sand, sand, sand, primer, SEM texture coat, and SEM paint. You can SEM coat the speaker grill too from parts express to blend in with the door if you want.

[ThreehundredC]

thats a good idea to just use the speaker cover im either gunna have to relocate these huge super tweets or trade em out i failed 3 separate panesl from early this morning til 6pm back to stage one this is hard

[ThreehundredC]

i am experienced with all those tools but dont have a router everything else was used just today

[Rell]

If you canceled out the tweeter you could skip everything else. I'm not sure how big that factory speaker grill cover is. If it would fit in that small area you could actually do the same thing, have speaker rings made. Cut a circle in the door panel there so the speaker ring would fit nice and snug inside it and just epoxy the speaker ring in.

Literally no fiberglass resin or chop mat would be needed at all.

[ThreehundredC]

1 8 will fit on the grill cover and maybe a regular tweeter

[ThreehundredC]

my problem is these seleniums have huge magnets and speaker and tweets are deep and heavy

[ThreehundredC]

here is one a guy used to sell

[ThreehundredC]

this one looks pretty simple but only 1 speaker

[ThreehundredC]

how can i make em just outta wood

[ThreehundredC]

tryna pop a single 8 and big super tweet per door something quick because i want to go to ao show this weekend