I'd go with Option Nick.
I still haven't decided if I'm going to use the thin aluminum I have here at the house or some type of plastic. I had to run to Walmart this morning for some other stuff, so while I was there, I grabbed a few cutting boards - one is only about 1/8" thick, but still pretty solid - and the other is about 1/4" think and very solid. Cost me a whopping total of about $2.70 for both combined. I'll experiment with both the aluminum and the cutting board plastic and see which works out better. Never tried cutting this type of plastic with a dremel before - I hear "melting" can be a problem... We'll see. I can basically just trace the stock speaker "baffle" and use that as a rough guide for the overall shape. I also have something to use to create the circle shape in the middle at the perfect size - as long as I can actually cut it out successfully with my dremel or jigsaw. I'll figure something out.The plastic doesn't have to be too thick to be a solid mount. I was just using what was cheap and easily available. The hole wasn't perfect either. Just marked the center as best as I could and used a cap to trace around for my cutting line.
I do have a jigsaw - but not so sure i have the right blade - I think I read about special "non-melting" blades? I'll look around at what I have and experiment a little though.If you have or can borrow a small jig saw its much easier imo to cut the rough shape. Used a rough grit sanding drum to finish. The faster the dremel speed the more melting. Trying to cut the plastic with the dremel will probably be more frustrating and slower than a jig saw with the right blade.
Thanks. So stupid question... Do you just use self-tapping screws to secure the speaker to the plastic or did you use a nut and a bolt? Being that the plastic is only about 1/8" think, I'm think that I'd be better off with nuts and bolts instead of self-tapping screws (not so sure how they'd hold over time).Looks good and will make a good solid mount.
Ok, thanks. I agree - I think a nut and bolt would be better in my case. I just so happen to have a whole "set" of small nuts, bolts, lock washers and regular washers that will be perfect for this - so I'll go with that. Will also help to reduce the change of a "slip" and the phillips screw-driver going right through my expensive-ass coaxials. Man, would that piss me off! I've never spent anywhere near this much for ANY speaker - let alone a tiny 3" speaker.... Hope it's worth the time, effort and $$$...The bolt and nut would probably be better for you. The board i used was close to 1/2 inch and these tweeters are much lighter than a small coax. Self tapping were fine for me. I actually made a tiny pilot hole to make sure there weren't any slips trying to secure the tweeters
Looks like it’s turning out great, jtrosky. Nice work! I’m going to have to get me a dremel... I know jack shit about dremels. What do you recommend to get started and for what you found useful for a job like this?Yeah, the space under the passenger seat is already taken with my under-seat subwoofer. I'm hoping I can fit the passive crossovers somewhere in the dash where you remove the dash "end caps". I don't remember how much room is in there (thinking one crossover on each side of the dash behind that "end cap" maybe). I'll find somewhere, I guess.
Thanks for all of your help - I appreciate it.
I'm far from a Dremel expert (in fact I'd say that I'm really a Dremel "noob"). However, I'll explain the basics that I know...Looks like it’s turning out great, jtrosky. Nice work! I’m going to have to get me a dremel... I know jack shit about dremels. What do you recommend to get started and for what you found useful for a job like this?
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You're as bad as the OP.You know... Dollar tree.... Their cutting boards work pretty well for for things. And I heard its only a dollar.
For those that are low on tools? You can Borrow a Router from a Local Tool shed in your neighborhood. Its free. Just Register.
To cut the shapes and make them smooth? Here is an easy way and CHEAP way to do it....
Just to be clear - I planned on creating proper "baffles" from the start. The "confusion" was just because I thought that when @SkizeR said "proper baffles", that he meant something that went around the back of the speaker - like an enclosure - kind of like the foam "baffles" that they sell for speakers, just with higher-quality materials. That is what I meant by the "I'm not doing all of that!" comment.You're as bad as the OP.
Creating proper baffles is simple.
Correction: I see that the OP finally just went and bought some plastic cutting boards and discovered just how simple and cheap making a proper baffle can be.