Door Speaker Builds

Step 1: First of all you need to measure up to see exactly where the speakers would fit. Then you can remove the door trims and use the pockets to mark out the shape of the new front and back sections on a sheet of hardboard.

Step 2: Now you have to make the speaker mounting plates, for this you have to mark out the hole for the speakers on the hardboard leaving a space at the edge for the grille. Then cut out the speaker plates so that you can get an idea of how much the door pocket replacements have to be extended by. Then mark around any bits that need to be chopped off.

Step 3: Once the door pocket replacement sections and the speaker mounting plates are made you can then start building them up. You need to have a recess so that the speakers can be mounted inside, to do this iron on an edge around the side of the speaker mounting plate. The edging is for trimming kitchen shelves so you should be able to get it from a DIY store.

Step 4: The framework can now be made by mounting the three sections on small legs. The original door pocket can be used to get the correct distance between the bottom two sections. The third section is angled up for better sound. It is all held together with a hot-melt glue gun.

Step 5: Next cover the frame in some stretchy cloth, it doesn't matter what colour as it won't be seen. Stretch it over the front and use the glue gun to stick it to the back.

Step 6: Mix some glass fibre resin with some hardener and paint it onto the cloth. Once it has gone hard apply about three coats and do any extra build up work inside if required.

Step 7: Once the resin is dry, the top section where the grille is to go needs to be cut out with a knife. If any lumps or bubbles appear on the main surface then just sand them smooth.

Step 8: Now use spraying adhesive on your pod and on the back of the vinyl (you may wish to use a different material).

Step 9: Then turn the pod over and stretch the vinyl over it, you may need an extra pair of hands for this to help with the stretching and the removal of creases. Some areas may need to be held in place while the glue sets. On the back use a staple gun to hold the vinyl in place and remove any excess material.

Step 10: Cut the vinyl hole for the speaker and you can then trim it with another material like carpet if desired. As the pod is hollow it is possible to mount a crossover inside if one is needed.

Step 11: To make a grille, mark out the shape on 15mm MDF. Cut out the inside section about 4mm from the marked line. Then cut around the outside section to give you the frame, be careful once it is cut out as 4mm thick MDF is fairly delicate. Spray glue onto this an stretch grille cloth over it.

Step 12: Now all you have to do is cut a hole in the door trim for the speaker and screw the pod in place. Then wire up the speaker, screw the speaker in place, slip in the grille and enjoy!