Now that I almost have my stereo install completed I thought I would put up some pictures to see if it may help anyone else with their car.
When I purchased my car it had a non factory Sony CD player and some upgraded Pioneer 4" door speakers along with the 4"x6" speakers in the rear deck. The rear speakers were destroyed by the Texas sun and the fronts were barley audible above 30mph. I removed the head unit and drove the car for nine months with no radio as I planned what I was going to do.
My installation consists of the following:
Denon DCT-100 CD Player
Phoenix Gold XS6600 6 channel amplifier
1 pair of Aura braxial MR62 speakers for the doors
1 MB Quart 10" subwoofer
I started by installing the speakers in the doors. The factory baffle was removed from the door panel and a spacer was made from a nylon cutting board. This spacer was screwed to the sheet metal door panel using three machine screws and locknuts, it has several reliefs cut into the back to allow it to sit flush on the panel.
After the spacer was installed I used some sound deadening material to cover the area near where the driver will be mounted. I could have covered to whole door but I don't want to remove too much of my cars character with sound deadening.
Next I reinstalled the leather door panel and screwed the driver into the nylon spacer through the door panel. There are 4 screws holding the driver and they must offset the other 3 holding the spacer so they don't collide. The 4 screw holes in the leather panel are the only permanent modifications I have made to the car.
I choose the Aura MR62s after reading about them on car stereo forum. They have small neo magnets and the basket has a deep taper so it isn't necessary to make the factory speaker hole any larger. They are no longer in production (haven't been since 1998) but I was able to find a NOS set complete in the box for well under $200 dollars on the same forum's classified section.
Since the tweeter is mounted on a bridge over the midbass driver there is also no need to cut an additional hole in the door panel like you would with a traditional component set.
You can find more info on them here,
http://www.aurasound.com/public/discontinued/frameset2.html
The speaker grill in place.
Door pockets reinstalled. The tweeter
just peaks over the top of the pocket.
Once the door speakers were installed I had to select a head unit. This wasn't easy as I wanted something with muted looks and excellent sound quality. I finally came across a new Denon DCT-100 on eBay that fit the bill perfectly. Denon only sells car stereos in Japan so these are pretty tough to get, it wasn't cheap but I couldn't be happier with the looks and sound. The illumination also changes to green and it has an RCA auxiliary input I use for an iPod. The head unit install was pretty straightforward so I didn't bother with pictures.
Now that I had a source and some speakers I mounted the amplifier in the trunk on a temporary board attached to the spare tire mount. No photos because it is currently ugly, I'll sort out something more permanent later.
With the mids and highs taken care of I now needed a subwoofer. I did a lot of research on 911 subwoofer enclosures and nothing I found exactly fit. I wanted a sub that was easily removable and had good output from a single driver without looking like a coffin in the back seat. After some searching I came across a used pair of MB Quart subs that matched up well with the power I had available and had a fairly shallow mounting depth of 5". I purchased both the subs with the intention of only using one. Once they were delivered I decided the most logical place to mount it would be in the rear passenger footwell inside a fiberglass enclosure.
To create the enclosure I removed the piece of carpet in the rear footwell and masked off the entire area with 2 layers of 2" masking tape in alternating directions. Once the area the enclosure would cover was masked I put a layer of aluminum foil down and pressed it into the footwell with a bunched up towel. The foil adds a moisture proof layer on top of the tape and will help the fiberglass mold release when the resin has set. I did two layers of chopped mat fiberglass in the car and then pulled the mold.
It came out looking something like this.
Before the MDF ring in the photo was added I put 3 more layers of fiberglass down for strength. Once those layers cured the MDF mounting ring for the driver was glued into to mold using scrap wood at the angle I wanted the speaker to sit.
Once the driver location was set I trimmed the rough edge of what will be the bottom of the enclosure.
Now the shape of the enclosure is pretty much determined. For the next step I stretched a fleece material over the ring and glued it into place on the edges using thick CA (hobby super glue) and some CA cure accelerator.
After trimming the fleece it looked like this.
