I have existing mid-bass speakers in my car's front doors and I want to reuse the space without modifying the doors. The existing speakers are 160mm units. I doubt I could modify my doors and have a result that looks acceptable.

The MLI-65s will almost fit. The depth is tight but will work. The problem is that the mounting flange is too large for the door panel. If I use the MLI-65 I will need to cut 5mm off of one side of the speaker's mounting flange to provide enough clearance to mount the door panel. It looks like there is a bit more than 6mm of flange width where the mounting holes are drilled through the flange.

Does anyone have any advice or experience to share? Is there 5mm that can be trimmed from one side of the flange?

Edited December 11, 200915 yr by MikeBrown

I have existing mid-bass speakers in my car's front doors and I want to reuse the space without modifying the doors. The existing speakers are 160mm units. I doubt I could modify my doors and have a result that looks acceptable.

The MLI-65s will almost fit. The depth is tight but will work. The problem is that the mounting flange is too large for the door panel. If I use the MLI-65 I will need to cut 5mm off of one side of the speaker's mounting flange to provide enough clearance to mount the door panel. It looks like there is a bit more than 6mm of flange width where the mounting holes are drilled through the flange.

Does anyone have any advice or experience to share? Is there 5mm that can be trimmed from one side of the flange?

Welcome dude.

Cutting the mounting flange? I would be very skeptical to try it. Are you sure this is the only way? There isnt any other options? If you put up a pic of the said door panel and speaker, we could all get a better look at it. Maybe then, someone might have a better idea.

If you have a stiff enough baffle you mount it to, shaving 2.5mm off each side could be acceptable. Will it affect performance? That will depend on how you finish of the rest of the install.

Here are pictures of the door panel and the housing that covers the speaker. The speaker is mounted to the door as shown by the last picture. I plan to build a new mount to replace the pod that is used for the original speaker. The pod is bolted to the door.

To use the MLI-65 I'll need to shave 5mm off of one side of the frame that will be at the top edge of the opening. I may need to shave half of that amount off of the opposite side of the frame.

Door panel exterior

Door panel interior

Close up of inside of speaker cover (there is about 1/4" of clearance at the top. This is where most of the flange would need to be removed. The inside diameter of the opening is 6 inches.)

Close up of exterior of speaker opening with a ruler.

Original speaker and door mounted pod

Edited December 11, 200915 yr by MikeBrown