Hey there,Hex said:
Make your own with 1/4" cutting board plastic if available. It will hold up better than MDF or other wood in a wet environment like the door can get. The metal itself requires no cutting.
Don't forget to deaden and seal the doors so your new speakers play like a true infinite baffle setup should.
Cut the door panel skin's plastic oval that sticks out where the speaker opening is. It is soft plastic and trims with a sharp razor blade. Then, gasket off the speaker from the door panel using closed-cell foam (the same stuff we deaden and seal with) so errant sound waves don't get trapped in the door, which makes for some horrible frequency response.
If you can, drill out the blank holes in the door skin so your new larger better speakers can play properly out to the cabin. Try to find the exact same size as the factory holes, and drill the skin so it looks stock.