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  #1  
Old 12-29-2014, 08:54 PM
wohnson89's Avatar
wohnson89 wohnson89 is offline
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Location: Wichita, Kansas, USA
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Write Up: How to Repair Cracked Package Tray Speaker Covers

It has come to my attention that almost all of the rear speaker covers for the SVX have become cracked and brittle over time. This wouldn't be a problem except they are discontinued by Subaru. I figured since I am having this problem, a few of you would also.

The best way would be to magically find a set still intact and use them, but since I didn't have that option, this is what I did.

****Disclaimer****
You are attempting this at your own risk. If you screw it up itís your fault not mine. I am not liable for broken bones, severed appendages, broken marriages, feelings of abandonment, or loss of appetite. If you experience any of these symptoms and they last for more than four hours see a doctor immediately.


Tools
-Razor blades/xacto knife
-Scissors
-Philips head screwdriver
-Needle nose pliers
-High temp hot glue gun
-Soldering iron w/wedge tip
-Propane Torch
-Respirator/Mask

Materials Required
-Various grits of sandpaper (80-180grit)
-Red scotch-brite
-Windex
-3M Spray adhesive (pn:08088)
-Performance Fabric Stereo cover (http://www.joann.com/performance-fab.../12505319.html) or equivalent stereo cover fabric. Half a yard is plenty.
-Small steel rod (paperclip, rivet stick, welding rod, whatever is available)

Process
Step One: Removing the package tray
Follow the instructions here to remove the rear package tray. http://www.subaru-svx.net/forum/showthread.php?t=54139

Step Two: Removing the speaker grills

Turn over the package tray and CAREULLY remove the Philips head screws that hold the speaker grills on. Some of the plastic inserts that the screws go into will break; this is okay as long as not all of them break.

Step three: Removing the mesh grill
Herein the problem lies: the plastic is shrinking while the metal stays stable, this is what causes the cracks. Fold straight the tabs on the back with a pair of needle nose pliers and CAREFULLY remove the mesh grill straight out of the outer grill along with the fabric dust cover. You will not be reusing this piece. I would suggest making a spaghetti strainer out of the two leftover grills.

Step four: Fixing the cracks
Put on your mask and heat up your soldering iron. Take the propane torch and heat up the steel rod, while holding it in the jaws of the pliers, until it is red hot. Set it into the back of the plastic letting it melt into the plastic in order to stabilize the crack. MAKE SURE TO WEAR YOUR RESPORATOR and have proper ventilation, the smoke that comes off is very carcinogenic (remember my disclaimer?).


After crack is stabilized, use the soldering iron to melt the plastic on the topside in order to further strengthen the crack. Make sure to go at least half way through the plastic with the tip to ensure a strong weld.


Step Five: Smoothing the frame

Start out with about 80grit depending on how messy your plastic welds got and work your way down to about 180 grit. If you have any low spots in the frame you can use gaffers tape (not duct tape) to fill in these low spots. If you do it right you shouldn't have to. Use a sample piece of fabric and stretch it across the cracks to make sure they don't show through. If they do keep sanding till they don't.



Continued in post two on account of the 10 pic rule.
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1989 Mazda RX7
2005 Mini Cooper S
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  #2  
Old 12-29-2014, 08:57 PM
wohnson89's Avatar
wohnson89 wohnson89 is offline
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Re: Write Up: How to Repair Cracked Package Tray Speaker Covers

Step Six: Stretching the fabric
DO NOT RE-INSTALL THE METAL GRILL, It will break all of your hard work (ask me how I know this).
Sand the back of the plastic casing with red scotch brite or 180 grit sandpaper. Use a clean paper towel and Windex to clean the back of the grill where you just sanded, this is very important for a strong bond. Heat up your industrial hot glue gun and make sure it is at full temp before you start. To check squirt a little bit on your hand and see if it leaves a blister. If it does, then it is ready (I'm just kidding, don't do this).


Trim a piece of fabric about a inch bigger all around than the grill.


Think of gluing the fabric down like torqueing lug-nuts. Follow the same sort of pattern. Once you get the glue in the initial spots, run beads of glue in between each one, following the same sort of pattern as before.



Next you want to trim away the excess with a blade of some kind. Be careful not to cut the fabric on the top. If that happens you will have to remove everything and start over. To do that, soak the whole thing in rubbing alcohol (or vodka if youíre Russian) and it should just easily peel away from the plastic frame. Anyway, the hard part is done.



Optional step: Re-gluing the carpet back on the package tray

After about 20 some odd years, the adhesive that holds down the carpet on the rear tray will probably be coming loose on the SVX. Now is a good time to remedy this situation. Mask off all of the tray that you donít want to spray adhesive on (unless you need some flypaper in your car), then spray both sides and wait the time directed on the can before you put things together.

Step Seven: Reinstalling the covers

Basically you just do the reverse of what you did before. If you feel any binding on screw as you are putting it in, take your propane torch and heat up the screw until itís not quite red hot and then slowly screw it in. This should prevent the plastic from cracking.


Step Eight: Everything else
Just do everything else the opposite of what you did before. Youíve made it this far, I bet you can figure it out.

Can you believe it, youíre actually done and your car looks just a little less old! Any questions feel free to contact me through pm or in this thread.
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1992 Subaru SVX LS-L Pearlie
1989 Mazda RX7
2005 Mini Cooper S
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  #3  
Old 12-30-2014, 01:48 PM
Sean486's Avatar
Sean486 Sean486 is offline
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Join Date: Jul 2005
Location: Mechanicsburg, PA
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Re: Write Up: How to Repair Cracked Package Tray Speaker Covers

Great write up, thanks.
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1992 SVX LSL 170k [I]4.44 Transmission, Ecutune TCU, Ecutune Stage 1, transmission cooler, silver STI BBS wheels, Sony Bluetooth double DIN head unit, Infinity front speakers, Lamin-X protected headlights
2010 Mazda 6 i Grand Touring - 120K
2007 Honda Odyssey EXL - 100K
2004 Mazda 3 S - 106K
-----------------------------------
1995 SVX Lsi Polo Sold at 118K 2007
2006 Mazda 5 Sold at 60K 2012
2005 Mazda 6i Sport Sold at 206K 2013 great car[/COLOR]
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  #4  
Old 12-30-2014, 02:48 PM
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fasteract7 fasteract7 is offline
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Location: NC
Posts: 398
Re: Write Up: How to Repair Cracked Package Tray Speaker Covers

Thanks mucho for taking the time to do a great DIY with the often neglected photo shots !!
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  #5  
Old 12-30-2014, 09:46 PM
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dannmarr dannmarr is offline
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Join Date: Jan 2005
Location: Pocono Lake, PA
Posts: 1,645
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Re: Write Up: How to Repair Cracked Package Tray Speaker Covers

Thanks! We need some more detailed "how to" like yours.
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Subaru SVX for fun
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Susuki SX4 for my older son
Ford Ranger for work
Mercedes Benz Sprinter for vacation trips,
EZ GO Golf cart for driving kids around gated community.
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