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.

[the1andonly]

looks nice will be doing my 2004 same way thanks for the great info,keep us posted

[woodsman]

very useful info thanks.

[FerNY]

I Did the same MOD without cutting the baffles, just making the inner center of the baffle a little big, you could use sand paper or a box cutter to start cutting around and finishing with sand paper. I used the same speaker! Polk 6.5 db651!!! Nice mod, less than 10 min per side. Using a rotary tool with a sand wheel start enlargign the inner of the baffle till the new speaker seats without problem. I start it with a box cutter all around, cause my rotary tool was dead with no charge! Then with a 5mm sheet foam from Michael's, fill around the speaker to keep it seal!
See pics

[Tieniber]

Oh man I did 6.5s with the MDF cutout last year after I got stiffed on some custom baffles. I really like this idea, I wonder if mine would sound any better done this way...

[drbodzin]

Originally Posted by Tieniber

Oh man I did 6.5s with the MDF cutout last year after I got stiffed on some custom baffles. I really like this idea, I wonder if mine would sound any better done this way...

I think you would get better sound as a mid & low range speaker seems to always sound better when you have it in an enclosure. But be sure to drill the holes in the baffle to allow air to pass in and out.

[rah rah 986]

I really like the use of the original enclosure. I have never used jb weld. Does it create a good bond?

You mentioned that you installed mid range co-ax speakers. I have heard that by design, the door speakers are to provide lower, bass like sound, and that the amp only sends lower frequency signals to the door speakers.

If true, I wonder how the mid range coax speakers work out, and, is the tweeter essentially unused?

[particlewave]

Originally Posted by rah rah 986

I really like the use of the original enclosure. I have never used jb weld. Does it create a good bond?

You mentioned that you installed mid range co-ax speakers. I have heard that by design, the door speakers are to provide lower, bass like sound, and that the amp only sends lower frequency signals to the door speakers.

If true, I wonder how the mid range coax speakers work out, and, is the tweeter essentially unused?

Aftermarket stereo
Not sure if the stock stereo is set up like you said, but it wasn't much good anyway.

[drbodzin]

Originally Posted by rah rah 986

I really like the use of the original enclosure. I have never used jb weld. Does it create a good bond?

You mentioned that you installed mid range co-ax speakers. I have heard that by design, the door speakers are to provide lower, bass like sound, and that the amp only sends lower frequency signals to the door speakers.

If true, I wonder how the mid range coax speakers work out, and, is the tweeter essentially unused?

The stock amp is setup to only use "sub-woofer" or base frequencies for the door speakers. And the mid-range speakers sounded HORRIBLE with the stock amp. But once I tore that sucker out and put in the new amp, all that changed and they sound amazing!

[drbodzin]

Originally Posted by rah rah 986

I really like the use of the original enclosure. I have never used jb weld. Does it create a good bond?

You mentioned that you installed mid range co-ax speakers. I have heard that by design, the door speakers are to provide lower, bass like sound, and that the amp only sends lower frequency signals to the door speakers.

If true, I wonder how the mid range coax speakers work out, and, is the tweeter essentially unused?

Oh, and JB Weld creates a very strong bond. However, I would not recommend using it to fix your engine parts (as I've seen on the web ). But for plastic and wood bonding, great stuff.

[adc]

Wish I'd seen this post a few days ago...

I've just installed Kicker KS60 into the stock OEM door baffles. This is apparently a 6" speaker, not the customary 6.5" size. I was able to simply screw it into the stock hole locations. It didn't fit into the recessed space so it sticks out more then the OEM speaker, but the door panel fit just fine on top of it.

I'm changing the head unit tomorrow, can't wait to see your amp recommendation as I didn't have anything planned for that.

[Rmon]

Where did you buy your inPhase woofer from?

[drbodzin]

Originally Posted by Rmon

Where did you buy your inPhase woofer from?

Go to ebay.co.uk and search "in phase power subwoofer"

I'm probably going to buy a second one to put behind the passenger seat. I love this product!

[MFozz]

Does anyone know the mounting depth using the OEM baffle?

[jeepdad]

Did you guys rewire the door speakers as rear speakers with her new head units?