My pop top door cards were in a right mess, somebody had fitted 4 inch speakers with no membrane and the hardboard had rotted away at the bottom, speaker was almost falling off one side and the covering all wrinkled and curled.
I was going to replace but I like a bargain and fixing these was so much cheaper.
I also wanted better speakers, I had a measure up and 6 inch speakers would not fit under the door pocket so I went for 5 inch.
took the cards off and this was what they looked like on the back.
peeled back the covering and slid some metal sheet between covering and the hardboard board to cut it square with a knife.
Then used 3mm expanded foam sheet and drew around door card covering and cut it out.
Marked clip hole with old hardboard where possible and where it was gone I fitted the new sheet temporarily, then placed door clip loosely in door with double sided tape on and held the door card in position, clips stick to new plastic sheet then mark and drill new holes.
cleaned up covering with a wire brush
3M VHB tape, lots of
hair drier to soften the plastic door card covering and VHB tape to make it stick and smooth out
went around the back with thin strips of VHB too
smoothed it out, I also varnished the back of the hardboard that was left.
made a template to check where the metalwork was in relation to the speaker holes
offered up speakers and I could see I need to space them off the doors to clear the speaker so I made some spacer rings with the router so that only the magnet protruded through the door card
and fitted
I realised that just adding one plastic sheet is not great because the water can run down and past whatever tape you use so I decided to use two sheets, one taped to the door and the other hanging down past the hole inside.
large thick plastic bag with two sides cut off so it’s joined at the top, one sheet pushed inside the door the other taped to the door.
happy with the result and being plastic sheet at the bottom it should never rot again.
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