Just wondering if anyone can help me out here. I'm in the market for a new set of front component speakers and have caught onto a deal for a Focal Polykevlar 165KF 6 1/2" component set. I'm jsut wondering if anybody has gone about installing these before? This speaker has a 71mm mounting depth- do you think i will have anyproblems even with the plastic bit behind the speaker cut out? I'm replacing a set of Rockford Fosgate 5 1/4" components in a 5th gen. Any help is greatly appreciated!
The 165mm woofer won't fit into the door panel trim. I think you're okay with depth once you cut off the baffle (stock I believe is around 55mm), it's diameter that's the killer. I just bought & installed the Focal Polyglass 160 v2 and that was a tight fit. The stock woofers are about 158mm, not sure how you'd install the 165mm woofer, unless you plan to trim the edges somehow.
Like ^^ he said, depth won't be a problem once the basket/baffle is out.
Your main concern is mounting the woofer. Most likely, you'll have to cut the stock mounting baffle to fit the woofers in.
Not looking to hijack the thread here, but has anyone managed to bolt the woofer directly to the metal door frame and still manage to 1) fit the speaker without touching the window guides and 2) manage to get the door trim panel back on and have it look stock? Just curious, because I'd love to mount the woofer to the metal instead of the plastic. I think the plastic is causing some coloration at certain frequencies and I'm not sure what to do about it. Any audio gurus here?
THATPRELUDEGUY has his Bostons mounted that way, but if the POS ever gets to taking pics like I requested 18 years ago, maybe he can tell you.
But yea, basically, you'll just need a mounting ring and cutting the door panel to clear the entire woofer. Leaving, of course, the mounting clip for the cover. If I ever redo mine, I'll be sure to document it.
Yes, some pics would be real sweet! I understand the bit about the mounting rings, may main concern is that to get the door panel to fit on top of that I'd need to cut so much of it off I wouldn't be able to bolt it back into the door. As you know, the door trim panel is held to the metal frame by a bunch of clips along the bottom and side edges, but around the speaker there are three screws that hold it to the metal. I fear that I'd lose those three screw holes and the panel will be flapping around down there. Know what I mean? I'm not sure how to avoid that.
That's my main concern as well.
However, I believe it's possible to trim just enough to fit the door panel over baffel/woofer without losing the 2 screw positions.
But my thought process takes me to this conclusion:
Since woofer will be mounted to door securely, any movement of the door panel itself is limited and no distortion will be cause by its movement. Further, velcro can probably be used to hold the door panel to the metal. I'm a friggin genius! Why didn't I think of this earlier?
Good thinking! I use velcro to hold the crossover to the metal door panel, I suppose velcro would work on the trim as well. In fact, it may even act as a dampener! Wow, you are a genius!
Thanks a lot guys. I was having a look at the space today and it certainly will be a tough squeeze! You guys have given me some ideas to try out anyway so thanks a lot!
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I use velcro to hold the crossover to the metal door panel, I suppose velcro would work on the trim as well. In fact, it may even act as a dampener! Wow, you are a genius! 
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