Front Door Speakers

• I bought 5.25 in speakers thinking that the HK front door was indeed 5.25 in. When I actually got the panel off I found a larger all-in-one size single cone speaker/spacer unit. It almost looks like a 6 in speaker. When I tried fitting the 5.25 in speaker into the hole but it was too small. You might actually be able to go with a 6 in. speaker.

• I knew from reading the posts that a spacer ring of some type would be necessary, just not how tall or what diameter was needed. Estimates were 1/2 inch to 1 inch. I felt it probably best to wait until I had the panel off and the speaker out to judge. Alot of installs used custom made spacers from various materials. The 1/2 inch plywood I chose worked very well.

• Armrest removal is for the '05 MINI. Earlier MINIs are easier to remove. Thanks Ian. (Again there are lots of good reads for removing the door panel but here's my procedure) The panel is attached to the door with (4) TORX screws. Noted in the pictures. The one of interest lies behind the armrest. Upon someone's advice I made my own armrest padding removal tool out of an old stiff plastic bottle. Cut in the proper area of the bottle the curvature of the tool can come out just right (see picture) It's about 4-5 inches long and 1-1 1/2 inches wide. The tool slips between the fabric and plastic on the forward part of the armrest and push it in. Pull the armrest toward the front of the Mini - it pops right off. Putting it back on is just the opposite except without the tool.

• Pry off the reflector using a small flat bladed screwdriver covered in electrical tape. (use this covering trick in all contacts with metal body parts)

• Pry off the tweeter/door handle covering. It is attached with about (6) clips around the circles.

• Remove the (4) TORX screws.

• Starting at the bottom somewhere use a large flat bladed screwdriver (wrapped in electrical tape again) to pop the first of (8) plastic clips. Once the first one undone use your hands to do the rest.

• The top of the panel is secured to the door with pinch clips along the window area. Lifting out and up over the top of the lock button does the trick. Your partially naked again.

• The speaker is held on with (4) screws. Undo them. (notice that the screw pattern is not symmetrical) This can present a problem if you do indeed have the correct size to fit the hole in that most speaker screw hole patterns are symmetrical. Adapters can be purchased from https://www.newministuff.com/shop/ . They can prevent you from having to build them yourself.

• I cut the old speaker wires but you can buy adapter also from https://www.newministuff.com/shop/ . I did notice something a little unsettling about the wire color coding though. Both doors had the same colors for (+) and (-) leads. I used my charts again to double check the right/left thing. I can only guess that somewhere between the HK amp and the door that the wires were changed. Both had the left fronts colors. I proceeded on and all came out OK so I'm happy.

• I traced the old HK speaker mount onto the plywood and cut away. This also allowed me to use the existing mounting holes. I did not drill new holes in the Mini's doors.

• I chose not to line the door with dynamat or the likes. This could have been a mistake at the time but all turned out OK. I don't think I needed it.

• I re-used the old HK speaker's sealant. (see picture) Carefully pulling it off and using contact cement to re-apply it to the plywood.

• I spliced the new speakers leads onto the Mini's cut wires and tie wrapped them to the cabling so as to avoid the window going up and down. Careful of positive/negative phasing.

• Mount the spacer plate first and check the clearance for your new speaker. I can not interfere with window operations. Think also about the panel clearance with the front of the speaker. Be sure you can press the panel back onto the door.

• I used RTV sealant or any gasket maker to seal the edge of the new speaker hole. Mount the speaker.

• Repeat this whole ordeal on the other side.

• Before putting the panels back on try the new speakers especially checking for right/left stuff.

  Reflector

  Armrest Removal Tool HK Speaker Seal