Automotive Door Pod creation and or instalation...

Rules of thumb:
1) Do not cut steel frame more than 20% larger than nearest hole (Don't be a smart *** and join the dots of factory holes to make a bigger hole either!)

2) Use pods/spacers to mount you speakers into this way you can put in larger, different shaped, custom designed enclosures, etc that do little damage to original trim and can be removed later if you so chose.

Assuming that you are putting speakers in to front door panels:

Remove door trimming and take note of removed components (Take pic's as you go it's easier)

Compare original speaker to new ones (in particular the depth of the cone) Factory tend to be shallow while after market ones deeper for better sound. Note depth difference.

Try your new speaker in the rough location you want it and wind down your window all the way and see if it will interfear with the mechanisms of the door. If it clears everything your laughing and just have to unscrew the old and replace with the new or...

Now the fun bit do the math on how much the difference is and how much you will have to space it out for it to fit into the door with out interfering with it's components, decide if you can deal with the speaker sticking out as far as it has to to fit, or can it be put in a different location. (Have a friend or family member help you with this so your hands are free to sit in your seat and feel it out, no point in putting it in if your not going to be happy with the end result)

Once your happy with your positioning make a blank up of a pod out of MDF (NOTE: MDF when cut/sanded creates toxic dust use appropriate Respiratory Protective Equipment (R.P.E.) such as a P2 paper mask as well as Personal Protective Equipment (P.P.E.) e.g. safety glasses, hearing protection and gloves) to make a shape that blends in with your doors contours and has a hole big enough for your new speaker to fit into. Dose not have to be perfect just yet as you shall have to mold it to suit what you want it to look like. Take your time and sit it in place till you are happy with the shape and placement. Make sure door closes and opens with pod.

Use this Blank to cut out a second pod just like this one (for the other door)

Shave off sharp corners

Match fabric to door trim (or go all out and highlight it in a contrasting cloure/pattern/texture)

If fabric stretch it over pod and staple into place (better yet glue some thin foam to pod first then use some spray addehisive to attach fabric to foam then stapel behind the pod to hold securely)

Vinal is a different story and requires spray adhesive heat and working it into position then stapling.
Good Idea to place speaker cage into place and secure to hold fabric around it. (Cut away excess in both cased inside cage and behind pod for a flat joining)

Mount speaker to pod and lay pod on a table placing door trim over it. Maneuver to correct position and use correct sized screws to join them together.

Connect wires

Test speaker

Replace modified door trim on to door

Repeat on opposite door

Fin.