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Old 03-15-2012, 09:25 AM
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Fitting Infinty Kappa 6x9 in the Front Doors.

Since I have not yet figured out how to do one big post with the pictures directly in the post instead of attachments, I am breaking this up in to multiple posts with the relevent pictures attached to said information. A little backstory: Since my 2008 WK Limited is the nicest vechile I have ever owned, the thought of tearing it apart (the inside anyways) just gave me chills. So, I bought front Infinty Kappa 3.5", the front 6x9's, and the rear 6.5", all topped off with an Infinty Bass Link Powered Subwoofer. The Kappas will be ran off the stock Boston Amp. Took it in and had it all installed. Sounds unbeliveably good for a simple upgrade, and the Bass Link thumps way more than you think it would. But, I noticed I had somever small front door rattle/resonance that I did not notice after the first few days. The shop I took it to said the Kappas were absolute beasts cpmared to the stock Boston speakers, and they had to use some spacers and such to get them to fit. After spending some time playing bass heavy music at very low levels and looking into the grill area I finally determined that the Kappas were so much bigger that in fact the surrounds were rubbing on the door panel, causing the BSR (Industry term for Buzz Squeak and Rattle). Coming to the realization that taking apart my beloved WK Limited's interior was inevitable, I decided to investigate first hand the issue and try to fix it.
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Old 03-15-2012, 09:27 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

So upon pulling the door panel off, I found what the problem was. You will see here that the factory has a built in "baffle" of sorts for the factory Boston 6x9, and this is completely overwhelmed by the Kappas.
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Old 03-15-2012, 09:30 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Some things to keep in mind when pulling the door panel on the 2008-2010 WK's is the "hidden screw" beneath the trim panel near the arm rest.
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Old 03-15-2012, 09:34 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

And don't lose the two little gaskets that seal the window channel sash against the door glass, for when you remove the sash, they are a little loose and can possiably fall down into the door.
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Old 03-15-2012, 09:38 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Before we get to the door panel modifications, here is what is needed to mount the Kappa 6x9. You need at MINIMUM a 1/2" spacer, as the shop said it was still prttey close to the glass when the window is all the way down, but there is clearance and does not touch the window tint. They wanted to go another 1/4", but would run out of room on the stock panel when trying to fit it back on. This was not a custom shop by they way, so they do not do what I am about to show here. Otherwise, they could fit a maybe a little taller spacer. As it is, 1/2" so far has worked great. Trust me, these Kappas are pretty damn big for a 6x9.
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Old 03-15-2012, 09:41 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

They also did not use small washers on the mounting screws, which I added. Word of caution, the mounting bosses that you screw into are actually plastic, so do not overtighten the speaker! Also, make sure you use a good, small washer with no burrs so as when you tighten everything down is does not dig into and/or tear the speakers surround.
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Old 03-15-2012, 09:45 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Ok, on to the door mod! I took some side cuts and made a starting point, then took the side cuts and cut vertical slats for my depth, careful not to go to deep to keep the "face" from cracking, then used said side cuts to "snip" the small pieces out.
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Old 03-15-2012, 09:47 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Then I went to the Dremel, large sanding drum. BE CAREFUL, as when the Dremel is sanding the plastic, it actually is melting the stuff into this super hot goo that can bead up and fly off. I got "bit" a couple times doing this, and it don't feel good.
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Old 03-15-2012, 09:48 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Next I used a good, sharp putty knife to finish triming any left over "flash".
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Old 03-15-2012, 09:51 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Followed by hand sanding with some 60 grit, finshed up with some 150 grit for a smooth, de-burred finish that would not cut into my Kappas it any contact was made.
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Old 03-15-2012, 09:56 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

Next up was the issue of the door panel fastners. Some have said you can get a couple uses out of them, WK Jeeps and Chysler say you need to replace them every time you pull the panel. I have pulled many panles off other cars before, and have never liked the idea of re-using the fastners, but in some cases it worked ok. So, using the part number from WK Jeeps, I went down to the Chrsyler Dealer and bought 20 of them, and they are nearly three dollars a piece. Yes, I'm that guy that will not bat an eye when he has to pay 52 dollars and change for 20 plastic door panel fastners. See my signature. Anyways, I will show you the difference between the new ones and the old ones that have be re-used only once.
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Old 03-15-2012, 09:58 AM
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Re: Fitting Infinty Kappa 6x9 in the Front Doors.

When you pull these, make sure you carefully transfer the little felt piece that sits on the fastner. The new ones do not come with this.
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