Here is an idea on how I upgraded my speakers.
|Standard R33 Speaker Housing
Apologies for the shakey hand picture!
You can see that in principal the housing is quite a good idea and that the flange on the end forms part of the door pocket, stopping all those essential items such as sweet wrappers disappearing behind the door card!
|Separate the back of the housing by cutting around the inside edge of the flange
Great so you have ruined your housing.. What's next? So we have a big hole, now to the cardboard and MDF!
Get it nicely sized so it fits snug and using the template that usually comes with the speakers on the box, place the speaker hole central to your template.
When your happy with the fit you can transfer this to the MDF and cut out. For this I used 9mm thick MDF, cutting out the speaker hole first and then the shape.
|Cutting out the shape from 9mm MDF
At this point I attached my mdf shape into the housing with a hot glue gun, these are available quite cheaply for around £10, to save on time I also used black glue sticks.
On the back side you will find that where we used 9mm MDF there is a nice 'channel' created between the housing and the MDF, fill this with glue and run a bead around the inside.
|MDF Insert, ready for bead of hot glue.
|Ready for mounting
|Mounted to car door, ready for door card to be put back on
I hope you have enjoyed my little 'howto' and found it at least entertaining!