As the years pass the stock speakers in our beloved ZJ's begin to lose the outer hinge due to the foam material rotting causing the sound output to become quite raspy and to most UN listenable. Most would not give a second thought to just tossing the old speakers out and replacing them with either an exact replacement or an aftermarket alternative, sometimes modifying the door panel to achieve proper fitment.
Well i was no different in this regard thinking well ill just find a source of replacement speakers and fix the problem, then i took a gander at the prices being demanded of such a replacement and about dropped a load in my pants!, well maybe not that extreme but since I'm relentlessly cheap and somewhat resourceful i decided ill just fix the speakers my self!!!.
Now for those that think its really not worth messing with the stock speakers as they are junk anyways and it better to lay down a chunk of change for replacements, this is more geared for those on a really tight budget, college students, those being relentlessly nagged by their significant other on how too much $$ has been spent on the jeep already and needs to be spent on others things, or plain ole cheap people like me that don't mind spending a minute amount of $$$ and a little time to fix something that is legitimately repairable!
Since the jeep i drive has rotting speakers i decided to share how to repair the outer hinge on the front speakers... The rear speakers are next, but for now on to the front speakers!.
Please bear with me i haven't figured out how to position the text with the picture yet...
Now lets get to the carnage! .....
Picture #1, the victim has been de-installed and the cloth cover removed from the speaker frame showing the completely rotted foam outer hinge.
Picture #2, The foam hinge remains have been cleaned off, ( i used lacquer thinner to clean the frame), also i carefully rubbed off the hinge remains from the back side of the speaker cone. I then carefully cleaned off the debris from the speaker, and i have carefully cut open the dust cover over the voice coil, (note i left a little bit of the dust cover attached, this is so i can place it back on when finished and not have any misalignment) the reason its cut open is so i can put paper spacers between the voice coil and the steel core evenly spacing the voice coil so it will not rub on the adjacent surfaces, (this is bad by the way and why causes the raspy sound in the first place!).
Picture #3, Closeup of the paper spacers placed on the backside of the voice coil centering the cone assembly.
Picture #4, I made a template for the fabric I'm going to make the hinge from, i used a piece of paper and a compass to draw out the circles, the inner diameter is exactly 4 inches, the outer diameter is 6 1/2 inches, this will leave a ring with the thickness of 1 1/4 inches, (please excuse the mistake on the picture, obviously i can't add!!
Picture #5, I have the template cut out and i have it placed on the fabric of choice, I used the template to mark the fabric so i can cut out the replacement hinge. BTW i highly suggest using old bed sheets that is cotton and of a decent thread count, if you don't have anything laying around go to a thrift store and see what they have for fabric remnants of that type?, color does not matter as this isn't going to be seen, just heard!.