DIY 6.5 Inch Door Speakers Using OEM Baffles

[drbodzin]

This is part of my 1998 Boxster Project: http://986forum.com/forums/show-tell-gallery/43078-1998-boxster-project-complete-restoration.html

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:

• https://docs.google.com/viewer?url=http%3A%2F%2Fimages2.wikia.nocookie.net %2F__cb20060612140228%2Fboxster%2Fimages%2Fb%2Fb6% 2FBoxster_speakers_update_article.pdf

• https://docs.google.com/viewer?url=http%3A%2F%2Fimages2.wikia.nocookie.net %2F__cb20061110190112%2Fboxster%2Fimages%2Fb%2Fbf% 2FDoor_Baffle_Template.pdf

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.