| DaveNagy
I wanted this to look stock. I may change speakers again and or want to avoid attention from some guy with a crowbar checking my install. (The car gets alot of people drooling on the windows.) I think the grills are fine (transparent) for mid bass and up. The whole door breaths (vibrates)as it is. I will be stiffining the door card and door with a heavy pliable pvc membrane and 1/2" pvc foam. If you want to cut out the door card you could mount 6" speakers flush and attach different grills. I think the card is parralel to the door. My flange is about 1 3/8" off the door with the foam ring making up the rest. In my "smush" test the foam was evenly flattened. If you are going to remove the OEM grill, do it, re-install the card and measure. But yea an 1 1/2" spacer would work. Apparantly almost any 6" speaker will fit if spaced out to clear the window stuff.
I have a lathe to use so I turned the spacer to fit the PVC.(See pic.) That's what I meant by pilot. You could just epoxy the pipe on. It also happens that the OD of the speaker just fits the ID of the pipe. The surround needs to be protected from touching. Some installs I have read about make me wonder.
Personally I would not worry about jamming the biggest speaker in the doors. The bass is not going to come from there.
There are threads and pics in MINI2 somewhere of the tweeter mount and the basket that snaps into the door. The original tweeter snaps in this basket and is almost same OD as the Pioneer I used. The dremel work is to remove the detents and open up the basket slightly.
cheers,
Ess | 
