How to Cut a Car Door Panel

Cutting a door panel is the first step to installing speakers.

If you plan on installing new speakers in your car that are larger than the current speakers, you will have to cut the door panel to complete the installation. This process is a little simpler now that one-piece molded plastic door panels are the norm. However, you will need to cut through this hard plastic, and that takes some skill and special knowledge along with the right tools.

Things You'll Need

• Screwdriver
• Window crank removal tool
• Jig saw
• Hole saw
• Drill

Instructions

1. Unscrew the door handle molding using a Phillips head screwdriver and remove it. Pry off the window crank handle then use a window handle clip tool to remove the C-shaped clip that holds this to the door. Pry it off completely then remove the window crank handle.

2. Remove the door panel from the door by prying off the plastic clip covers and clips, and disassembling any additional door handle hardware.

3. Place the door panel onto a work bench and carefully locate the area to be cut. Draw an exact line around this area, marking off the piece that will be cut from the door panel.

4. Brace the door panel with hand clamps or a vise in a position that allows you to make the cut. There should be clearance below the panel and on all sides where you intend to cut.

5. Cut the panel with a jigsaw and a thin metal blade designed for cutting PVC or plastic fittings. Work only as fast as the blade allows. Do not rush the cut as the plastic will break or chip. If you intend to make a round cut for stereo speakers, use a fine-toothed hole saw and a power drill to make your cut. The hole saw must be the exact same size as the final hole.

References

• Upholster: Recovering a Door Panel
• Term Pro: Cutting Door Panels for Speakers

Resources

• Crutchfield: Installing Car Speakers