Will Ng

To get my mind off my divorce and layoff, I completed my front speaker installation with the free time I now have. Since the car came with the Bose system, I had to gut the Bose door enclosures of their amps and odd 1.3 Ohm drivers. I removed the Bose wiring from the door harnesses as well...didn't need that thick power and ground wire and shielded RCA cable anymore. To use the Bose enclosures, I cut a plywood template to take a 4" midwoofer.
I chose JBL GTO 4.2c components. I decided to mount the tweeters in the dash grill location for an easier time. Ideally, the tweeters should go in the doors, right through the wood trim, in front of the door handle. But I didn't think it was worth the risk to the door panel.
I was going to seal the Bose enclosures' ports to make them acoustic suspension. But retaining the (transmission line?) port did produce deeper bass.
So, I only added fiber fill and left the ports open.
FYI, I discovered having the tweeters in the dash made for an overly bright to harsh high end output. Definitely would have sounded better off axis in the doors. Hopefully some resistors will resolve the harshness.

To finish things off, I covered my cracked grills with black grill cloth to pretty things up a bit.
Some pics below:

<img src="http://pictureposter.audiworld.com/38606/200q_stereo_speakers2.jpg">

<img src="http://pictureposter.audiworld.com/38606/200q_stereo_speakers3.jpg">

<img src="http://pictureposter.audiworld.com/38606/200q_stereo_speakers4.jpg">

<img src="http://pictureposter.audiworld.com/38606/200q_stereo_speakers5.jpg">

<img src="http://pictureposter.audiworld.com/38606/200q_stereo_speakers6.jpg">

audiqv8

Great job Will especially the grill, looks professional.

One nice thing about the divorce no more high heels going through the grill.

Will Ng

Well, not from my wife's shoes!
;-)

CharlesV8QExec

<center><img src="http://pictureposter.audiworld.com/75922/103-0369_img.jpg"></center><p>Those look sharp. I was going to do the same thing with the 5.25" speakers I just bought. Do you think I can fit 5.25" mids in the Bose housings? I think i might go the same route too and cover my grills as that does set it off nicely. Thanks for letting us see those great pics.

RussB

If so, you're a better craftsman than I.

Of what material are they made? What was the hole diameter and what was the speaker diameter? (Or is hole circle more relevant?)

Will Ng

1/4" MDF would be better due to its density, but hard to find at that thickness.

The speaker hole diameter is determined by the brand/model speaker you have. Most come with a template. Just trace the Bose driver onto the wood. Then just center the new speaker's template onto the Bose pattern and trace the hole.
The pics hide my messy workmanship actually. I tried a RotoZip-type attachment and bit on my Dremel and it cut like ***. Use a standard jigsaw for better control.

Will Ng

You have about 2" of clearance with a 1/4" thick template. But I think the diameter may be too big.
The Bose driver was 4.5". Your required opening may be larger.

SmellenDelicious

Can you give me a brief review on materials, tools etc.?

Just for the covers.

Thanks in advance.

Will Ng

I re-used the existing grills.
I welded the cracked plastic with a tip designed for that purpose, with a Weller soldering gun.
After thoroughly cleaning the grill, I spayed a light coating of 3M No.77 spray adhesive onto the front of the grill. I stretched black grill cloth over the front and sides.
Then sprayed adhesive to the back edges and folded the grill cloth over, trim the excess with a utility blade.
Let dry and you're done.
Re-attach to door panel as desired...I used velcro, but double sided foam tape, or gluing it will work.

rooster 2

Slick work Wil, looks really nice, works well too, I bet