LeRox

I've removed the rear panels, to repair the warped edge along the lower edge of the rear window (they came out pretty well) and of course the original speakers were shot.

Well got new speakers that will require some panel modification. The existing hole is approx. 3 3/4" diameter, and the new speakers will require 3 7/8" to fit. Need to grind/cut/? out the difference for new speaker. Ideas?

KraigG

Find another set of speakers that fit the original holes. No cutting required, and there are literally thousands of speakers out there to choose from.

taffelman

You could try to make a mounting ring that lifts the speaker a little out from the hole if there is space behind the panel. Shouldn't take much to allow the extra 3 mm difference.

Alan

Since you only need an extra 1/8" several options:

The mounting ring idea may get you enough clearance - however for looks you probably need to make one (router with circle cutter) and then cover it with interior trim matched vinyl/leather... lot of work - I did it for depth issues - so warning you may need to check for depth too...

Another alternative is to peel back the vinyl/leather around the opening and trim back any of the moulded hardboard for the ~ 1/16 inch you need with a sharp knife - then use a nibbling tool to nibble all around the aluminum plate - there should still be plenty left for strength and using a nibbler you should be safe from damaging the trim (be careful with the knife though). Also check to see if you only really need 3 7/8" at the speaker frame ribs - if so maybe you do localized enlargement only...?

Alan

Mike Frye

I see you've done some fiberglass work there. How about removing the trim ring that's there, fiberglassing the hole over and then cutting out what you need from that. The fiberglass should be as strong as the old trim ring was I would think.

LeRox

Thanks all for the suggestions.

I actually found a very nice set of speakers (as compared to the originals) that I thought would fit perfectly (the screw holes lined up, depth ok, etc). The thinking was "THIS IS THE LAST TIME I"M TAKING THE REAR PANELS OUT" and might as well upgrade to the best speaker for that area.

Alen, I think when I trim the leather back, that may give me enough room, but it will be close.

Mike, you gave me an idea to remove the trim ring (its only being held by to rivets), drill rivets, cut/nibble trim ring, re-rivet, it the above trim job is not enough.

Let you know how this works out and I’m looking forward to the rear panel re-install.

LeRox

Well, after really looking at all the optings, another idea came to mind and worked. I got the idea to mount speakers to the bottom of the rear panel.

First trim leather around speaker.

Alan

Err... I think you will find there isn't enough depth behind the panel when installed....

Alan

LeRox

Well, after listing and really looking at all the options, another idea came to mind and worked. I got the idea to mount speakers to the bottom of the rear panel.

Attachment 272617

First trim leather around speaker hole.
Attachment 272618
Remove one of the clips attached to the trim ring
Attachment 272619
Slide speaker into the other 3 clips, careful not to dammage top of speaker on the existing rivets.
Attachment 272621
Replace 4th clip
Attachment 272620
Re-align speaker/clips w/ screws prior to attaching speaker covers. Also note the repaired warped panel (upper left of speaker), this was were the panel was prior to straightening. May touch up old wear mark w/ black leather dye (future).
Attachment 272622
Stock cover fitted.
Attachment 272624
After market cover.
Attachment 272627

Not sure which speaker cover I'll go with, but the nice thing about doing it this way, I can change speaker cover pretty easy.

Which cover would you choose??

Alan

Ok so your quarterpanel speakers are in the more rearward location than mine - so maybe there is a lot more room there - are you sure before you get too far into it though?

In the more frontal location (late model) the depth is very very limited...

Alan

LeRox

Thanks Allen for your thoughts. I accidentally posted something before I knew it, and that’s how you squeaked your way between the posts...my bad (still getting used to this forum stuff).

I feel pretty confident these will work fine; b/c the depth of the new speaker vs. old is almost identical. BTY, did you have a preference on the speaker covers?

Alan

Personally I like the Sonys much more.. actually similar to the later factory style.

Alan