How to Replace the Foam Suspension of a Speaker Cone

The foam surround protects the speaker.

Over time, the foam suspension that surrounds the speaker can become dried out and damaged, requiring a repair that can be costly. Replacing the foam using a speaker foam kit can help the speaker sound new once again and save you money as well. Most speaker brands and models have speaker kits available for this purpose that can be ordered or bought online, and the simple installation makes this one project that almost anyone can handle.

Things You'll Need

• Speaker foam kit
• Screwdriver
• Razor knife

Instructions

1. Place an order for a foam replacement kit. These are available online, at music stores or at speaker repair shops. They usually cost between $25 and $50 and will include all the parts you need to make the repair, including the foam and the glue. Use the speaker specifications and model number to order the correct kit; the foam shape and size will vary by manufacturer.

2. Remove the grille to access the speaker that needs repairing. Carefully pull the grille off, paying carefully attention to handling it to prevent the grille from puncturing the speaker cone. Some grilles are attached with Velcro. Simply pull on the tab for the grill or use a screwdriver to pry the grille off. Remove the speaker by unscrewing the screws on the flange, and disconnect the wires.

3. Remove the old foam by carefully pulling it off of the speaker flange. Use a razor knife or blade to remove all of the foam that is still glued to the flange, and try your best to remove all of the old glue as well. The new foam will bond better to the foam if the old glue has been removed. Throw all of the old material away as it is useless.

4. Size up the foam from the kit. Put it up against the flange of the speaker to see how it will be installed. Some speaker foam is separated as to not cover screw holes. Line up the various pieces, or use the razor knife to cut the pieces to size for the new foam installation.

5. Apply glue to the foam and carefully put it into place. Press down relatively hard on the foam so that the glue sticks to the speaker cone. Clean up any excess glue with a water-soaked rag. Continue this process until all of the pieces are in place and the speaker is surrounded in foam. Allow the glue to dry for 24 hours. Reconnect the speaker wires and reinstall the speaker and grill by screwing the speaker into the cabinet.

Tips & Warnings

• Be careful not to slip with the razor knife while cleaning off the old foam; it could puncture the speaker cone or your skin.

References

• Speakerworks: Sizing Surrounds For Your Speakers