Just got done working on the baffles and it was going quite well till I had actually cut them out and did a test fit. Everything went downhill from there. With two baffles, a total of 1", the mid had perfect clearance depth-wise. Unfortunately, the basket was still hitting the door so I figured I'd give it a shot and add another 0.5" baffle. The mid went in perfectly, no issues.
Just by looking at it, it looked like it extended quite a bit. I put the door panel on and it doesn't come near fitting on properly. I cut part of the door panel again, and even accidentally cut part of the exterior of the door panel, //content.invisioncic.com/y282845/emoticons/frown.gif.a3531fa0534503350665a1e957861287.gif, and it still would not fit. I have about 1" of a gap to fill.
My only option that I can think of is to cut a good chunk out of the dark brown (lower) portion of the door panel around where the baffle would go. I know the baffles are in squares in the pictures, but even if I cut them in the shape so it would fit inside the huge hole (where the speaker grill used to be) it may not work because of the mounting holes. As I'm typing this, I'm thinking that it might be possible to actually do that, but I'll have to double check some other day.
I actually do have a second option, which is to have a shop or maybe even another DIY'er who can make this all look real nice. If anyone knows they can do this type of work and make it look real good, let me know.
Also, if anyone has any ideas, feel free to blurt it out. I'm open to suggestions, because there may be things I'm not thinking of that could help me a great a mount.
Anyhow, on with the pictures. Here's a picture of what the mid WOULD look like if everything fit properly.
Side view of the gap
Top view of the gap
Side shot
Where I screwed up like an idiot and cut through the door panel
Baffles with the door panel off