Polk DB522 Install

[jmd349]

Recently upgraded the head unit last week, so naturally I just had to go ahead and order new speakers that arrived today. DB402’s in the dash and the 5.25” DB522’s in the roll bar. After some serious PITA I gave up mounting the DB522 covers onto the roll bar and I just put the speakers in without covers just for the sake of getting it done a getting to listen to the new setup. With that said, anyone got any tips or tricks to get them mounted?

Maybe I’m just making it harder than it has to be.

 

[rasband]

Watching so I can follow suit. Mine have been exposed for a year and a half...

 

[Nightshade]

I just reused the factory covers.

 

[Moab]

Mine went right in. Holes lined up for the screws no problem.

Can you post some pics?

 

[jmd349]

Mine went right in. Holes lined up for the screws no problem.

Can you post some pics?

Wish I had it that easy. Don’t think the pics really help any but here’s what I got.

 

[jmd349]

I just reused the factory covers.

I thought that was a great idea, so I tried it this morning. Turned out the old covers we so brittle the screw holes broke on a couple so it rattled. Grr. Back to square one.

 

[rasband]

I attempted to use the factory covers and it didn't seem to fit, maybe I will give it another shot and hopefully not get rattles :/

 

[Darsmith]

I designed up and 3D printed adapter/spacer rings and used the Jeep factory covers with the 522s. I did have to slightly round out the speaker upper outside ring to work with the factory covers. Took off about 1/8" where the factory cover screws passed through. Kind of hard to explain, but it works great. This is on an '03 Sahara.

 

[Darsmith]

I also printed pods and installed 522s up front.

 

[Moab]

It appears there is a difference between pre and post 2002 soundbars. On my '99 there is plastic cloth covering the sound bar. On 2002 and later I don't think that is the case. (I think there are other differences as well.) Here's a longer thread on trying to get 6.5's into the soundbar holes. That may help.

https://wranglertjforum.com/threads...ar-without-cutting-and-other-questions.29314/
On my '99 the speakers holes and cover holes lined right up. But maybe that isn't the case with 2002 and later. You may have to drill new holes for the new covers. I would think it would be worth it. Since your old ones were trashed. And they look like crap compared to the nicer ones that come with the Polks.

I don't see holes for the covers on your's. Is that the case? Where did the original covers screw into?

 

[Moab]

Here's your answer. You have speaker pods. Not a sound bar. I think 2002 and later have the pods. This guy simply used half the screw holes for the speaker and the other 2 or 3 screw holes for the covers.

"To attach the speakers to the pods, I used the original screws that came out of the stock speakers to set the first screw in place. Since I was going to use the Polk Grill, I left the other 3 original mounting holes empty and used the other screw holes in the speaker to screw into the pod. For this, I used the screws that came with the DB651s (self tapping) to screw in 3 other holes, not the original mounting holes though. Then after getting the speaker in, I set the Polk Grill on top of the 4 original holes and with the 3 remaining holes not used, I screwed the grill into place.
Here is the look post install from the Top down. "

https://www.wranglerforum.com/threads/stock-soundbar-speaker-size.166222/page-2

 

[jmd349]

Here's your answer. You have speaker pods. Not a sound bar. I think 2002 and later have the pods. This guy simply used half the screw holes for the speaker and the other 2 or 3 screw holes for the covers.

"To attach the speakers to the pods, I used the original screws that came out of the stock speakers to set the first screw in place. Since I was going to use the Polk Grill, I left the other 3 original mounting holes empty and used the other screw holes in the speaker to screw into the pod. For this, I used the screws that came with the DB651s (self tapping) to screw in 3 other holes, not the original mounting holes though. Then after getting the speaker in, I set the Polk Grill on top of the 4 original holes and with the 3 remaining holes not used, I screwed the grill into place.
Here is the look post install from the Top down. "

https://Wrangler Forum/threads/stock-soundbar-speaker-size.166222/page-2

Ahh that just may work. The link attached is dead, but I understand what you’re saying. I’ll give that a try. Thanks!

 

[Akitadog]

My solution was with a 1/4" aluminum plate. tapped for the drivers bolts and used an XT60 Lipo connector to be able to remove them. Crossover tucked inside with poly batten.

 

[Armandors]

I designed up and 3D printed adapter/spacer rings and used the Jeep factory covers with the 522s. I did have to slightly round out the speaker upper outside ring to work with the factory covers. Took off about 1/8" where the factory cover screws passed through. Kind of hard to explain, but it works great. This is on an '03 Sahara.

Hi man, I got here looking for this same issue. Do you happen to have your STL files for that spacer? I want to do the same. TIA