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Old 10-27-2012, 09:43 AM   #1
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Join Date: May 2012
Location: Avon Park, Florida
Posts: 295
My Ride: 2002 BMW 325i
Rear 6.5" replaced by 8" custom install!

Friend had funds to upgrade door speakers and rear speakers, so I got him to follow this up grade. Just replaced the front 6.5's with a set of kickers. Rear was the real thing. First removed and covered parcel shelf with black leather. Ensuring speaker mounts were blacked out also. While shelf was out used sawz all and removed the little humps that sit below the 6.5's. pretty much giving a flat mating surface. Made template of underside of deck and transferred to 1/2" mdf. Cut out template and also made 6.5" holes that line up with the mounting holes in the shelf. Covered mdf with gray felt fabric almost matching trunk. Before reinstalling shelf drilled 1/4 inch holes through metal deck and mdf for securing bolts to go through. Used 6 screws and nuts to secure mdf to underside of deck. Used black silicone type caulking to seal around exterior of Mdf. Reinstalled rear shelf. Here's the good part. Used high density expanding foam to seal area from 6.5" hole in mdf to 6.5" inch hole in shelf. Placed duct tape around outline of opening in top on shelf and on the underside of the mdf. Just to keep foam from expanding onto surrounding materials. Remember to place plastic on floor of trunk to catch any foam. Sprayed foam into cavity between shelf and metal deck and mdf. Just enough to get it to come out so the cavity and can be trimmed off with a long knife, to make a perfect cylinder when hardened. Once cut and shaped used brush on plasti coat to black it out and smooth out foam surface. Forgot to mention loctite on bolts so they don't vibrate loose. Rounded heads of carriage bolts sink Into mdf a little so not really noticeable. Remove duct tape. Small bead of clear silicone around mounting surface of 8's, screwed into mdf. Just about as air tight as you can get, using trunk as IB. Ran wires along back of wall, flat to mdf. Invisable unless you look under deck!

Last edited by sfcjetjr; 11-25-2012 at 10:17 AM.
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