Right boys and girls!
Here's how I built door pods to house 17cm speakers in the front of my mk2. Since I have put a mk3 dash in mine I have to watch out they don't fowl the dash (like the last attempt did!)
first of all cut 2 rings out of MDF. the thicker the better. I used some 18mm as that will give a good base to screw the speaker to. After all we want the best bass possible in the front of the car as we can get out of a 17cm speaker. You don't have to cut a perfect circle as this will mostly be covered with fibreglass, but try and get it less like a 50p and more rounded
the original plan was to screw the MDF straight to the pocket and cover it until I shut the passenger door and couldn't open my lower glovebox. Back to the drawning board then!
I wanted to sink the original MDF ring into the standard pocket and aim it slightly up into the car to carry the midrange skyward in the hope it'll sound better. After I'd drawn round where the MDF ring sat on the pocket I attacked it with the power file. If anyone doesn't know what one of these is think of a chainsaw with a belt of sand paper instead of a chain. This is a awesome power tool and useful for so many things. Using this I took to enlarging the hole to sink the MDF ring in. After a while and a few trial and errors I managed to get the ring in there perfectly. I then secured the ring with the gluegun so it wouldn't move at all and I could also use the pocket until I get around to fibreglassing it over and smooth all those ridges and gaps out. Once I've done that I'll cover it with the same carpet as I did the boot and hopefully have some decent door builds
You can see how much I've sunk the MDF ring into the pod here.
to be continued...