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‚Äôve 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).
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).
Apply sound deadening to outer skin.
Add diffuser panels behind the speaker.
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.
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.
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.
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)?
Solder the trimmed speaker wires onto speaker. Don't use crimp terminals because their two best traits are falling off and creating resistance.
Heat shrink around the terminals to protect them. Unlike electrical tape, heat shrink will not begin moving after a couple of months.
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.