Thought I'd post up a quick build log/noob tutorial on cutting speaker baffles. I'll be doing it pretty ghetto but someone could learn from this I guess. Heads up, I will not be including photos of everything. I already ran out of daylight after one ring today.
Two blocks of MDF, one 1/2" and one 3/4"...I used particleboard from Lowe's (shut up, it works)
#8 (or #10 ) sheet metal screws, 1" in length
Additional sheet metal screws, 1.5" in length
A drill with bits
Beer (yes, it's a necessity, trust me)
To start things off, anyone who has owned one of the new-ish VW/Audi cars and tried a DIY speaker swap have learned two things. One: VW is retarded and riveted in their speaker baffles as well as bolted them from the rear. They call it anti-theft, I call it just plain stupid. Two: even if you remove the speaker from the stock baffle, a new 6.5" will not fit without severe modification, so you have two choices. You can either jury-rig one in there or you can create new baffles. I've chosen to take the second option.
To drill out the rivets, I took a masonry bit and drilled down on the rivet until it spun freely. From there, I used a pair of dike cutters (*snicker*) to cut out the rest of the rivet. Once all the caps were removed, I pulled the baffle off and hammered out what was left of the rivets and pulled them out of the inner door skin. Once you're done, you end up with something like this:
You will use this to make the shape for your baffles. Since it doesn't lay flat, cut the leads from the terminals on the bottom and cut out the empty cup from the top so the baffle will lay flat. Now it looks like this:
Trace around the baffle with a wood pencil (or Sharpie, I prefer Sharpie) both inside and out on the 1/2" board. Using the speaker brackets from your new set of speakers, trace and mark the drilling points/openings. Do this again with just the speaker bracket on the 3/4" to make your rings. You'll end up with this:
Ignore the cut, I was testing out a saw that couldn't complete and has since been returned...FIRST LESSON LEARNED: you will need a jig that plugs in. The cordless ones won't last.
The following parts I didn't photograph because I was running out of daylight and doing this solo. Take your jigsaw and cut around the outer perimeter of the shape. When you get to the inner ring, drill a couple pilot holes so you can fit your jigsaw blade in and trace the lines you made.
Once you're done with that, you'll want to cover your baffle in something to waterproof it. Some people use Thompson's WaterSeal, others bedliner, I used Plasti-Dip because I could find it easily at Lowe's and it'll do the same damn thing. Here's what one of my rings looked like after the first coat:
This is where I've run out of sunlight and charge on my jig, so I'll be resuming tommorrow.
You may now commence flaming my amateur and ghetto tactics. Good day.