Installing 6.5" speakers in stock 5.25" door openings (with lots of pics)

[coolwind57]

Not so much a elaborate technical Tech Write up of a difficult endeavor, but I didn't see much on this topic (especially one with pics) so I dove in on this project and snapped some pictures along way.  Hope it helps anyone wanting to do this.  

 

I had some 6.5" aftermarket speakers laying around in the garage.  My MJ doors take 5.25" speakers, so could I easily install these without too much modification?  Yep.  Sure can.

 

So here's what the original 5.25" speaker looks like:

 

 

Tearing the protective fabric and one sees the construction materials used back in the day.

 

That speaker wasn't too bad, but the other one was completely destroyed inside.  I didn't get a shot of it, but the foam securing the paper cone to the frame was non-existent.   So next, we have a comparison of the 5.25" and the 6.5" aftermarket:

 

The 6.5s will fit in the speaker hole, but barely.  The speaker connectors were making contact, so I took my angle grinder and cut out a notch.  With this notch, my 6.5's fit flush and like a glove in the original speaker holes. 

 

So, I decided to reuse the factory MJ speaker connectors, as I found that they actually fit quite securely on the aftermarket tabs of the speaker...and I didn't want any additional joints in my wiring.  I carefully pulled them from their assembly using a utility knife and I wrapped them with electrical tape because I could not find my dang shrink tubing kit.   One certainly can do the wiring different, but I felt good about this method, as I'm certain that it'll hold up well to future door slammings and typical everyday use.  Plus, I didn't have to go drag out my solder iron.   

 

So again, I wrapped my connection in electrical tape and then placed the speakers in their new home.  You can't reuse the original mounting screwholes, so I took self-tapping screws and drove them home, securing the speaker in the door.  

 

By the way, the white plastic liner you see in my door interior came from a later model XJ.  I pulled it from a junkyard and paid like a dollar for it.  It is much thicker than the clear plastic film that they used in 1989, and with proper adhesive, it is very-much reusable.  Had to make a couple custom cuts, but works well and for cheap.

 

Installed the door panels and she looks great (and stock). 

 

I'll admit that the built in tweeter of the aftermarket is making light contact with that grill you see in the photo, but does not appear to interfere with anything.  I see no issues with this.  I'm happy, man.  Compared to my crappy factory speakers, it now sounds like Steve Perry is sitting along side me.

Edited October 1, 2017 by coolwind57
wrong pic at the end.

[Swampy]

Man That looks awesome. I would LOVE to put new speakers in but I am not sure how to get the door panels off and I Don't want to break anything