[mklett33]

Hello and welcome to the How to Increase Mid Bass and Build Custom Speaker adapters Tutorial! Have you ever added new aftermarket speakers in a door or dash location only to be disappointed with the output in the mid bass region? Sure the higher frequencies sound great but it just seems like your mid bass is lacking in comparison to the factory speakers? This is a common problem that can be solved through the use of new custom speaker adapters and a few other tricks. In this thread you will learn how you can build custom speaker adapters using composite materials that will not only last forever, but through the addition of foam rings, sound amazing and increase the mid bass within the passenger compartment. Let’s begin!

Here we have our average stock speaker bracket:



The problem with this bracket is that it is simply not large enough to house our new component speaker. But there are some good design elements of it that we want to note and include in the making of our new bracket.

First off it is made of plastic. This is good because it will never decompose like wood. It’s also very strong and stable. This is good because we don’t want to lose any acoustical energy with unnecessary flexing of the mounting baffle. We will want to make sure our new bracket is also made of composite materials.

Secondly it spaces the speakers away from the inside of the door. This is critical because it makes the speaker stay out of the way of the window mechanism within the door and also brings the speaker closer to the hole in the door panel where sound will pass through to the passenger compartment. We want to be sure we also space our speaker away from the door.

Finally there is a foam ring around the outside of the baffle. This helps to direct all of the sound from the front wave of the speaker through the grill mesh or hole in the factory door panel. If this ring is not there then the sound waves are free to bounce around within the door panel or dash which can lead to cancelation or unwanted vibrations within the panel itself. We will need to include a foam ring in order to direct the sound as desired.

Lets start fabricating! Please note that every step is outlined in full detail within the video at the end of this post. I took a few pictures just to give a rough overview of whats going on. The video is much better at showing the process.

I started with tracing out the stock adapter onto a piece of .25 thick ABS.

 

[mklett33]

I then rough cut this piece out using a jig saw and then used my router table to copy the piece perfectly using a flush trim bit:







In order to space the speaker I am using .50” HDPE. I started with making a wooden circle template out of MDF, then transferred that to the HDPE, once again via the router table.





I used that same template to cut out the same inner hole on the ABS.



In order to assemble everything I used CA glue to glue the HDPE to the ABS, then mounting hardware to secure the speaker to the HDPE. Be sure to predrill all holes to avoid cracking.



At this point we have made new adapters that not only fit our new speaker, but are made of composites and space the speaker away from the door. Now its time to add the foam rings. I found a supplier that makes the foam rings in multiple different sizes and that are pre cut with adhesive. These were super easy to apply, just peel and stick.



The foam kits also come with a piece for the back of the adapter that allow you to shield the speaker from any dripping water within the panel, and they isolate the adapter from the surface it bolts to.

 

[mklett33]

Once bolted back in all you need to do is apply your factory panel and give them a listen! Do note that some applications will require modification of the foam, but in my case the foam bridged the gap between the speaker flange and the inside of the door panel perfectly.

 

[mklett33]

To see every step of this process in much more detail, watch here:



I hope you enjoyed this thread! Let me know what you think, and if you do give this a try, be sure to take some pictures and share them with me here!

 

[Hanatsu]

Nice work!

 

[Kornnut]

Where did you find the foam rings at?

 

[dallasneon]

Where did you find the foam rings at?

X2 I've been looking for precut foam rings for a while.


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[Niebur3]

Maybe here?????

Sound Connection 6 ½

 

[analogrocker]

In order to assemble everything I used CA glue to glue the HDPE to the ABS, then mounting hardware to secure the speaker to the HDPE. Be sure to predrill all holes to avoid cracking.

Is CA glue by itself strong enough to bond the ABS to the HDPE in the long term? I remember reading on here that a special adhesive made just for HDPE was required for bonding plastics to HDPE. From what I read, mechanical fasteners are best for bonding plastics together.

 

[deeep]

really cool stuff and great video

Id be worried about the rear foam pieces falling off after some time considering how hot door skins can get in summer.

 

[deeep]

Oh, and, any concern with water + foam and any potential mold issue?

 

[chuyler1]

Before you spend $50 on two pieces of foam, you should check to see what Home Depot has in stock.

I posted these photos back in 2006...

Cost me about $5.00 They have other sizes too. Most people don't need such a giant ring. If it is less than an inch, try their foam weather stripping.

 

[MUGWUMP]

Any foam that isn't closed cell is going to fill with moisture and then rot and fall apart. It will probably stink also. If it's made to go in a car, fine. That air conditioning foam looks really soft and ready to hold lots of water. I doubt it last more than a year or 2 before it's falling apart.

EDIT: Thanks for your videos Mklett. I've learned quite a bit from them even though I think you need to hire a better writer for some of your jokes.

The information parts are great though

 

[chuyler1]

It lasted 4 years and never got wet because it was on the door panel side. It's no different than the foam ring around the original speaker.

I would never put something like that (or the rings in the original post) inside the door though. For that I have used strips of ensolite to protect the back of the speaker or I find a way to use the original plastic protectors.

Simple test for something that goes in the door. Poor water on it. Squeeze. If it acts like a sponge, you don't want it in the cavity of your door....but it should be fine between the inner door panel and the door itself.

 

[UNFORGIVEN]

So these rings are effective?
for 25$ shipped I can't see why it wouldn't be worth a try

 

[deeep]

Id want just the front ring....I wouldnt trust anything behind the speaker. Deadener will never fall off but foam rings?

 

[Blinkybill]

Any tips on routing the plastic? I.e router speed which bits are best e.t.c

 

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Is CA glue by itself strong enough to bond the ABS to the HDPE in the long term? I remember reading on here that a special adhesive made just for HDPE was required for bonding plastics to HDPE. From what I read, mechanical fasteners are best for bonding plastics together.

You are correct. HDPE would need to be mechanically attached to other substrates. You can drill and tap it, so that helps...


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[jb4674]

Nice but, not everyone owns/have access to all those tools and materials. Mark should sell custom made speaker baffles for different cars and then he wouldn't have to "ask for support"

 

[HertzGuy]

Nice but, not everyone owns/have access to all those tools and materials. Mark should sell custom made speaker baffles for different cars and then he wouldn't have to "ask for support"

My thoughts Exactly! He does nice work and really good walk through video's. But only do work for customers on the forums that he is apart of! Would keep him busy and he could get all the support he Wanted!