Cutting door panels to fit 6.5" speakers
 

Hey all, i plan on installing some marine speakers in my rear door panel, not the hatch.. I was wondering what would be the best and most accurate tool to use to make a 6.5 hole??

I feel like I've used just about everything with a cutting blade (and have seen some jobs done without)

First choice is a 6.5" hole saw with a really beefy electic drill. Second choice is a "buzz" saw like this one:
http://www.harborfreight.com/media/c...image_2397.jpg
And then maybe a jig-saw or sawz-all as a last choice.

Before you cut though check your depth and make sure the window won't hit the speaker when it's rolled down.

yea i don't have a saw zaw or jigsaw "yet" and i have been thinking of using my dremel with the cutting blade but i tested it on another piece of plastic and it didn't cut so well. The whole saw sounds like the best way to go but that's a big freaking whole saw, it'll prob catch somewhere and f things up.. I do have a spare panel so i will test on that..

As for clearance on the rear window i have plenty, the actual design of the window looks like it was prepared for speakers in the door but never went through with it.. So yes i have clearance, plus with it being on the panel itself it saves me about 1/2".

Hmmm... i don't like hack jobs so i want to get this right.. Thanks for the reply, don't know if ill get to many back.

98jeepsrt6, make yourself a templet out of plywood, 3/8" will do, then with your dremel and a router bearing attached cut along the inside of the templet and you've got a smooth hole.

Cherockee, hi neighbor

GTP

Hey guys, heres an update on the speaker cut out in rear door panel.. not hatch. Well i have got the holes cut already, i used my dremel and like ^^ stated i made a template out of some durable cardboard. The hard stuff not the flimsy ****.. lol It was kind off a pain since i didnt have clamps to hold it in place but i marked the hole with a marker as well just in case it moved..

My holes are not perfect because a dremel and plastic dont mix well together.. the plastic melts around it.. But the speaker are a perfect fit.. comes close to the bottom of the door but theres about a 1/4 inch gap in btween when i shut the door and the inside panel..

Once ive got it all together ill post some pics..

Thanks for the suggestions.

:thumbup1: COOL can't wait to see the pics :thumbup1:



GTP

Ok, here you go guys.. My audio system.