This is part of my 1998 Boxster Project:
1998 Boxster Project - Complete Restoration
I've installed a new stereo system into my Boxster, including new 6.5" Polk Audio Speakers for the doors. They're mid-range speakers. I will go over the entire install in another post. In this one, I just want to show how I was able to use the stock OEM Baffles with larger speakers.
When I search for how to install larger door speakers, all I found was a DIY for replacing the OEM baffle with a cutout of MDF.
Here if what I found:
I wanted to use the OEM baffles instead, so here is what I did.
First I removed the speakers from the baffle.
Using a Dremel with a cutting wheel, I removed the face and the top and bottom sides surrounding the speaker opening. I cut along the seam of the baffle. I left the edge where the speaker wire attach intack so that the MDF would be sandwiched in between.
I then cutout squares of cardboard to create a template for the MDF I would cutout.
Once I had the template, I cutout squares of 1/2" MDF that I would secure to the baffles. I secured the MDF to the baffles with JB Weld. Once it was hardened I sealed the any openings where the MDF butt against the plastic with silicone. I later realize there really wasn't a need to seal the openings, as I ended up drilling holes in the back of the baffle to allow air to pass in and out of it.
Once I stalled the modified baffles in the doors, I saw I had to trim a bit of the MDF away so the door panel would fit properly. Notice the holes I drilled in the back of the baffle to allow air to pass in and out.
And here is the final step. I installed my new Polk Audio 6.5" Mid Range speakers. The entire system sounds amazing.
I will post the Amp, Head Unit, Dash Speakers and Rear Speakers I used as well. Just wanted to show how to get larger speakers in the doors without losing the baffles.