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Old 05-12-2009, 21:28   #1 (permalink)
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Read How To: Install Midrange Speakers Into A Falcon Door.

Hey guys,

I've had quite a few people email me asking if I could throw a quick tutorial together on how to install speakers into Falcon and Territory doors (as I’ve done a few tutorials for various other forums). So without further ado; this is how to install midrange drivers into Falcon doors (i'll do the Territory as a separate thread).

Step one: Take one original door complete from factory. Remove the plastic splash guard and the goo that holds the plastic on (don't stress about water getting through - the deadening will stop it).



Step two: Apply sound deadening to outer skin.



Step three: Add diffuser panels behind the speaker.



Step four: Run aftermarket speaker cables through the door loom tubes. This is important because there's no fuse between the amplifier and the speakers - if the factory wires are too small they'll get hot.



Step five: Make the baffles. These take a similar shape to the factory ones and screw into the factory screw holes (thus avoiding damaging the door). They're usually constructed from MDF but we've made them from perspex or even 6061 alloy depending on application. If they are MDF then they should be painted with polyester resin to avoid absorbing water.



Step six: Sound deaden inner skin and remove all air bubbles. Make sure you leave enough clearance for door handle and lock control rods to move freely. Also leave a little deadening around the top of the speaker hole to act as a 'roof' against water when it rains.



Step seven: Screw the baffle onto the door and seal the baffle onto the deadening with gap filler. Make sure you also install a gasket between the speaker and the spacers because air leaks out here too (ever tried to run your car without a head gasket)?



Step eight: Solder the trimmed speaker wires onto speaker. Don't use crimp terminals because their two best traits are falling off and creating resistance.



Step nine: Heat shrink around the terminals to protect them. Unlike electrical tape, heat shrink will not begin moving after a couple of months.



Step ten: Sit back and enjoy your new found midbass. This is what the door looks like when complete:



So there you have it; one Falcon door with midranges installed. Using this method you have about 68mm of mounting depth (using 18mm MDF). Any deeper than that and your speaker might impact the door trim during large excursions.
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Old 05-12-2009, 21:35   #2 (permalink)
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Re: How To Install Midrange Speakers Into A Falcon Door.

If you want to further enhance your listening experience (staging and imaging wise) then you'll probably want to make a set of a-pillars to mount your tweeters on (in the case of a two way component set) or midranges and tweeters (in the case of a three way set) like this:





If you wish to read more about what sound deadening, diffuser panels and sealing does click here and click here.

If you wish to find out more about staging, imaging and how our ears relate to them both click here and click here.

I hope that helps you guys out.
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Old 02-13-2011, 12:45   #3 (permalink)
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Re: How To Install Midrange Speakers Into A Falcon Door.

After receiving about ten emails regarding this tutorial during this weekend just gone I thought I'd better bump this thread. :D
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