[Octavia vRS mk1] Pictorial: Installing new component speakers with crossover in door

[kirk]

I treated my Octavia vRS '04 with some new component speakers for the front doors from Rainbow Audio. I decided to take some photographic evidence on the fitting process. I only depict installation on the passenger side front door. The driver's door is identical, except for the removal and installation of the door card, which is slightly different.

Since pictures tell more than words, I will not describe the work in detail.

Removing door card

Based on Rob's excellent guide for uninstalling the rear door card.

Step 1: Unscrew torx screws

Step 2: Pop out electric window switch and unscrew screw

Step 3: Remove trim from door handle

Step 4: Remove two screws from door handle

Step 5: Pop out tweeter casing perpendicular to door

Step 6: Disconnect wire for door handle and door light

Step 7: Lift door card straight up and revel

Edited 21 July, 2009 by kirk

[kirk]

Speaker installation and tweaking

Loosely based on Scodillac's instructions on how to tweak woofer mounting.

Step 1: Remove original speaker

Step 2: Remove speaker mount

Step 3: Remove speaker sealing membrane

Note: in the picture above, this metal edge will hit speakers that are too deep. It can easily be bent or cut away, if one wants to install deeper speakers.

Step 4: Create waterproof seal which allows speaker to breathe into door (out of duct tape)

NOTE: Eave goes into door, so that water should not poor into speaker bay, unless car is upside down.

Step 5: Check speaker mount edge for air leaks

Edited 21 July, 2009 by kirk

[kirk]

Step 6: Insulate speaker mount edge with thick two-sided tape

Step 7: Install speaker mount

Step 8: Make speaker wires to connect new tweeter with VAG speaker connector

NOTE: You can buy adapters to connect to VAG speaker connectors from for example ebay. Google for 'PC2-805'

Step 9: Connect speaker wires between woofer-crossover, tweeter-crossover and input-crossover

Step 10: Modify crossover to fit door installation

Step 11: (Re-)fasten styrofoam insulation piece to door with thick two-sided tape

Step 12: Fasten crossover onto styrofoam insulation piece with thick two-sided tape

Edited 21 July, 2009 by kirk

[kirk]

Step 13: Connect speaker components with crossover and install woofer (some cotton added, polyester filling would be better)

Step 14: Remove original tweeter from tweeter mount

Step 15: Install new tweeter to tweeter mount (mine needed to be tweaked with a Dremel to fit snug)

Step 16: Fasten door card (reverse of removal)

NOTE: If door handle doesn't work properly, make sure door handle wire plastic plug is in groove.

[gigy]

Very useful guide for me, thanks