Searched the web for a 'how to', found nothing so had a crack myself. If you don't have the Bose pods which can already accommodate the larger speakers then this is an option. Materials: MDF 18mm Plywood 8mm Spray On Contact Adhesive FULA FOAM (expanding polyurethane foam) Automotive carpet or leather (or your choice of cover) Tools: Jigsaw Staple Gun Pointy nose pliers Tradie knife Screw driver/drill with philips head tech bit Sanding block and 180 sandpaper Trace your door skin for the pod location and shape, transfer it to the 8mm plywood and cut it out. Reverse the plywood cut-out for opposite door template and repeat. Measure your 6.5" speaker for circumference and cut a hoop from the 18mm MDF. Join the 2 together in proposed location with screws and liquid nails (or similar strong glue) Cut out the speaker hole. Find a rag with some stretching property and stretch it over half the pod base, staple it in place from behind making sure its good and tight. Take the can of FULA FOAM and follow the instructions with the nozzle tucked into the Rag. When you think you have filled the space half as much as you need to then stop, this shit expands when drying. Repeat for the other side and leave it to set for an hour. Once it has set remove the staples/rag. Shave off/shape the foam if you have to but if you used the right amount of foam and your rag was taught enough then it will be good to go. Sand it down if you're really fussy. Spray on your adhesive front and back and stretch on your cover. Staple it into place on the back and cut out the material in the speaker hole. Fit the speaker and job is done. A lightweight 6.5" speaker pod that you can screw to your door skin using the existing holes from your OEM speaker grill, so if you ever want to go back to original it isn't any hassle. With speaker placed in the correct position there is no modification to the door skin whatsoever.
I bought the 6.5 speaker panels from CZP and bought 6.5 speakers. The bloody speakers don't fit the bloody holes!! Oh the speakers I bought were: Jaycar Speakers - CAT. NO. CS2402 6.5" Kevlar Coaxial Speaker w/ Silk Dome Tweeter
these look fantastic!.. i am VERY impressed. Would you be tempted to make any of these ? only variation i would make is in trimming and it would be doing black leather to match the door over the carpet.. BUT each to their own taste it looks great mate!
