Example: Fitting 10inch Freeair pioneer sub woofers to the doors of a late model commodore.
Materials:
Small pieces of MDF
1-2litres of fibreglass resin
50mL catalyst
1 square meter of matting
Stretchable material Fleeche
Masking tape
Cheap paint brushes
Rubber gloves
Face mask
Angle grinder, electric dremel sander and jigsaw are required.
How to:
First up i took the door trim off and worked out made an MDF piece that will attached to the door, I worked out the available depth so then i could work out how far the speaker will have to it out. I use little MDF legs to hold the MDF ring up at an angle and screwed it together. I could then place the speaker on spacer to see how far the magnet sticks out the back. I had to raise the lag another 1cm to make it fit. Once i was happy with the angle i then staple gunned some material on the inside of the ring. You could put it on the outside as it may be difficult to fit the staple gone into a small 8inch or 6.5inch spacer.
Then i added fibreglass resin onto the fleeche material and then two layers of matting to make it very strong. This spacer has to be strong as it will support most of the weight of the speaker.
I Then placed the Spacer against the door trim and it showed me what needed to be cut from the door trim. I then got the angle grinder out and cut the entire bottom corner off the door trim. I carefully trimmed the map pocket plastic as i will be keeping the map pocket. I made sure i cut a bit extra just so i have some adjustment when on the door. Also make sure you take off some of the vinyl as the fibreglass doesn't stick to vinyl very well but the door trim underneith it sticks perfectly.
Then i attached the door trim and spacer to the door and got everything into position so the doors would still shut properly, i gave 5mm clearance around the spacer for when the fibreglass and vinyl goes over the top.
Then i stretches material across the spacer and staple gunned it onto the door trim making a nice curve (well it was pretty bad curve actually due to the complex shape). Try to get your hand behind the door so the staples goes nicely into the door trim without cracking.
I then coated all the material in resin making sure the resin ran up onto the door trim, once it was dried i then angle grinded any folds which made holes in the material. I then put a layer of fibreglass over the top and things were starting to take shape. I then gave it a light sand and sprayed some black paint over the top.
I then tested fitted the door trims to the door, i had to slightly trim the hole in the door skin to fit the magnet it, basically it meant enlarging the hole towards the window winder. I then screwed everything the speakers up and gave them a run.
Just need to sand it down and vinyl the bottom half of the door trim. I still get to keep the map pocket, its only 2inchs shorter than the stock. I will including more details and pictures of the vinyling when its done.