I wanted to replace my stock non-Bose speakers with two pairs of 6.5" coaxial speakers in the doors, and I noticed that after removing the front door panels, the stock baffle has the Clarion speaker built into it. I was wondering if there is a set of baffles like those that I can buy, or would I have to resort to trying to make my own custom ones out of MDF? I really don't have the tools for such a job, so I'd much rather purchase something as similar to the stock ones as I can. I'm nearly finished installing my 4-channel amp, but I know if I connect it to the stock speakers, they won't be around much longer...

As always, your assistance is greatly appreciated.

 

Just make your own. Remember, they don't have to be perfect, they will be hidden. After Don showed me how to make them I would never buy another set. Especially if you have a jigsaw. A power sander helps but is not necessary. All you have to do is measure the diameter using your speakers and cut away.

 

I do have a jigsaw... It's true that it will be hidden, but I'd like to make it as close to the stock size as possible. As I said before, I'm planning on putting 6.5" speakers in there, and eventually going with a set of 6.5" separates...

Do you mind sharing the wealth with me so I can get started on that project? I'd appreciate it greatly...

 

(1) Put a nail in the MDF
(2) Attach a length of string to a pencil for your desired inner radius...attach the other end to the nail
(3) Draw your circle
(4) Drill a hole in the center of the ring
(5) Using the jig, cut a straight line from the middle of the ring to right before the circle...repeat for each of 8 cardinal directions
(6) Now, slowly turn your jig into the ring and follow the pencil marking
(7) Mark the outer radius and repeat step 2
(8) Now just drill a hole on the outside and follow around...this end does not need to be as clean. so just cut as the blade will allow.

 

I do it ghetto in comparison but that will work. I just place the speaker cone down and trace the circle on the wood. Measure the lip(distance between the outside edge of the basket to the first ridge, there is your ring think ness. Hack away.always cut the center ring before the outer ring. It is much easier to use the stability of the whole piece of MDF than trying to hold the baffle and cut the inner circle.

 

Or just get yourself a rotozip/craftsman all-in-one/dewalt rotory tool and use a circle cutter. I just picked up a refurb'd craftsman all in one with LOTS of accessories (incl. circle cutter, plunge router, etc) for $15 on eBay (plus $15 shipping). Ease of use puts jigsaws to shame for most car audio projects.

 

Great price. If I could get one for that I would buy it. I have heard many people speak highly of that method, as far as ease and accuracy.

 

I'm looking at a used one on e-bay right now. I think I'll pounce on it as long as the price remains low. Thanks for the advice.

BTW - How thick a piece of MDF should I use for the baffles? I have 3/8" right now, but I'm taking suggestions.

 

Just got my set of Infinity Kappa/Reference 2-ways and my Kicker L5 and the ported enclosure are on their way! and now I need to make these baffles. Any suggestions before I get this show on the road would be appreciated...

I'm thinking I should get a piece of 1/2" MDF and make two pieces per speaker - one "doughnut" to attach the speaker to and another one to attach to the door frame, and just use the 1" screws that came with the speakers to attach both pieces of MDF with, and use a little wood glue to seal the two pieces of MDF together, and use the stock speaker as a guide to where the stock screws should go, and just re-use those screws. The stock Clarion speaker has that plastic mounting piece that's about 1" thick, so I figure this would give me enough clearance for the front speakers (mounting depth = 2 7/16"; cutout diameter of 5 1/2") to avoid scratching my front window tint. The rear speaker mounting depth is 2 1/4"; cutout diameter of 5". I'm going to see if Home Depot rents out a Rotozip tool so I can get it done faster since I can't seem to locate my jigsaw right now...

Also, is there something I can spray the MDF with to keep it from getting affected by moisture that may find it's way in there? I thought I remember someone mentioning that they did something like that when they made their own speaker baffles a while back. Let me know!

Thanks in advance...