HELP! Melted Crossovers

BroncoHound
10+ year member

Junior Member
Alright guys, so the woofers in my Boston Acoustics Pro60 components stopped worked a while ago. I initially thought the amplifier had gone out because, while I was still getting sound out of my tweeters, the sound was not very powerful (read: wouldn't get very loud). So, I had the backseat out of my truck and was testing the amplifier by replacing it with one from my other truck (which resulted in no change, BTW) when I noticed that the woofer section of my crossovers are melted through. Obviously this is why my woofers are not working any longer, as it has happened to both sets of crossovers. Now, aside from ordering new crossovers, I am trying to figure out WHY this happened so I don't melt the new crossovers that I am replacing these with.

So here is how everything is set up. First off, for reference sake, here is the back of my amplifier, a JL Audio 300/4.

13204.png


Okay, so I am just powering the Pro60 set off this amplifier. My rear door speakers are stock and are powered off the head unit; not amplified. So, i have one set of RCA's coming back to the 300/4 which are then hooked to splitters and connected to both the front and rear imputs on the amplifier. The front speaker outputs are connected in a bridged manner and run to the input on the passenger side crossover, which is then wired individually to the tweeter and woofer on the passenger side. The rear speaker outputs are connected in a bridged manner and run to the input on the driver side crossover, which is then wired individually to the tweeter and woofer on the driver side. The amplifier is in 4 channel input mode, both front and rear input voltage is set to "low," both front and rear frequency range is set to "1x," both front and rear filter slope is set to "12db," and both the front and rear filter mode is set to "off." The filter frequency of both front and rear channels is set to around 60hZ and the input sensitivity is about half way up on both front and rear.

With the way it is set up, the only thing I can see that I don't like (the guy that initially installed the system did the settings for the amplifier and I never got around to changing them around since it sounded good) is that I think the filter mode should be set to "HP" to filter the lowest frequencies which should go to the subwoofers instead of the components, correct? Could not having that filter mode selected right have caused the melting of the crossovers? I can't see how it would, but I don't know for sure which is why I am asking here. I REALLY don't want to install a set of new crossovers without figuring out why these ones burned up and I can't do that without you guys. Please help!

Thanks,

Bud

 
With this site being strictly dedicated to car audio and with as many seemingly knowledgeable audiophiles on this forum, NOBODY has even the slightest idea what is going on here? I find that hard to believe. HELP, someone please!

 
I have installed many many systems and have never seen a melted crossover so I couldnt even begin to tell you what happened.

If I had to fathom a guess though it would be that your speakers wires may have grounded out.

Can you post pics of the melted x-overs?

 
I have to remove the back seat in order to get to them (they are mounted on the back firewall of a Dodge Quad Cab 3500) but will try to run out there and do that real quick.

One think I was just looking at in the owners manual. They are rated at 125watts RMS, 250watts peak. Could I be pushing too much power to them with the bridged 300/4? I thought, being that they are a fairly high dollar set of components that they should be able to handle the 300/4 with relative ease, but was I wrong in this? Should I run them off just the front 2 channels instead of bridged to push maximum power?

 
Alright, I just went out there and pulled the seats to take some pictures. I have never pulled the driver side back seat and inspected the crossover on that side, so I made the mistake of assuming that, since both midbass speakers were not functioning and both tweeters were functioning at a lower output that what was wrong with the passenger side must also be wrong with the driver side. Turns out, the passenger side crossover is the only melted one. The driver side crossover looks undamaged. That makes this all the more complexing to me. Why would both sides be inoperable if only one crossover was fried? Anyway, here are the pictures of the crossovers. The first two pictures are of the passenger side crossover. The last three are of the driver side. Any and all help would be GREATLY appreciated!

Crossovers01.jpg


Crossovers02.jpg


Crossovers03.jpg


Crossovers04.jpg


Crossovers05.jpg


 
No ideas as to HOW this is happening? I don't want to just return them, get news ones in, install them, and they burn my truck down when they melt again. I want to fix the problem, not just replace what was broken. Maybe just a bad crossover? These components are less than 6 months old, just FYI.

 
It looks like they have vent holes on the sides. Maybe having the seat on top of them didn't allow them to vent...those are some big *** crossovers...never seen anything like that. Can you pull it out and get the cover off? Check the damage. What's with the vent thing next to them...does that get hot? Maybe on the exhaust side of the car and heat comes back in through there....just throwing out ideas...

 
You know, now that you mention it, the passenger side is the exhaust side of the truck and it is a 5.9L Cummins Turbo Diesel so the exhaust temps get pretty ****ed hot (especially down here in south Texas). The vents on the back of the cab are just that; vents to the space between the cab and the bed of the truck. I really don't want to open them up because if BA is willing to replace them I don't want them thinking I tinkered with it and caused the meltdown...

Any other ideas guys?

 
Well I looked at the crossovers a bit more....it seems like a foreign object got jammed in there when it was hot, based on the way the plastic is bent up...I think if it just got hot and melted a little it would have kept almost the same shape....

 
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BroncoHound

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