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With some help from a friend with a 3D printer and CAD experience in SolidWorks, I was able to make an adapter ring that allows the factory speaker grill to be used with aftermarket 4" speaker. This design could be fairly easily used/adapted for any 4" speaker. My the speaker in my car is a Morel 402 Hybrid (2way speaker).
Here is the first prototype, the plan was to use a 3D model for fitment and then use a CNC machine to mill it out of a more durable material like Delrin or Aluminum. However, the prototype looks really good and I will use this unless we have durability issues. It took us about 1hr to measure and create the design in Solidworks and 30min to 3D print.
Here is the back side. The step you are seeing is what will hold the speaker against the door. I had to sand the inside diameter smooth since the 3D printing has a rough texture.
The 3D printed threads actually worked really well. The overall diameter is about 1mm too small. We will adjust and reprint.
The ring fit very snug on the speaker and the mounting on the panel is solid and very professional.
The Problem:
Anyone who has looked at installing non-factory speakers has had the dilemma of how to fit the factory speaker grills on the door panels. As we all know the factory speaker grills were threaded onto the factory speaker. The factory speakers use standard dimension mounting holes and securing bolts, but have a non standard ring glued to the outside of the speaker to allow the grills to be threaded.
Here is the factory speaker, you can see the lager plastic ring with mounting holes. This outside edge us threaded for the grill.
This photo shows the initial installation by the professional installers. They were able to cut the ring from the OEM speaker and glue it to the aftermarket speaker. This worked good in holding the grill on but did not work well in holding the speaker in the door. After about 3months of use the speaker would pop out of the door when closing, taking the grill with it. Ultimately the plastic fitting broke.
Last edited by Michael Benno; 08-16-2016 at 02:19 PM.
Nice work! I'm gearing up to do something like that with the 6-inch speakers. Are going to post the design to Sculptio (or similar venture that allows the design to be private) so that anyone can get them printed?
Yes, I'll post the files. We need to adjust the outer diameter +1mm to get better thread engagement, and do a test fitting before publishing the files.
Nice work. What material did you print in? ABS? PLA?
For those of you without access to a 3D printer check out 3Dhubs.com. You can find someone in your area that can print the file in a material you specify. Part will be more expensive than printing yourself but way cheaper than buying a 3D printer.
You can also do it over the internet via a half-dozen or more sites.
I've used Sculpteo before. With this site, you don't have to make the design files public; You can make public the ability for folks to print the part.
You can also do it over the internet via a half-dozen or more sites.
I've used Sculpteo before. With this site, you don't have to make the design files public; You can make public the ability for folks to print the part.
Nice work. I had to improvise when I did mine by reusing the old ones. Even though one of them broke I was still able to use it and it holds fine. At least now we have an option.
08-15-2016, 07:27 PM
DIY Door speaker adapter for OEM grill
