Speaker Repair Instructions

Speaker Refoaming Instructions

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Parts Needed:

1. Remove speaker from cabinet. Note correct wire hook up (+ vs. -) for later installation.

2. Remove any large pieces of remaining foam by simply pulling them away from the cone and frame. If there is a gasket on top of the old foam, remove it with the utility knife and save for later reuse. See figure # 1. DO NOT remove masonite trim rings on old Advent, Dahlquist DQ-10, DQ-20, and AR 11” woofers.

3. Scrape all remaining foam/glue from frame with edge of utility knife or wood chisel. Soften any foam/glue on cone edge using rubbing alcohol or lacquer thinner. Remove residue by GENTLY scraping with utility knife or wood chisel. See figure # 2.

4. Before gluing, check for proper cone and frame fit. Small variances of less than 1/8” are OK.  If the new edge fits cone, but the outer lip is too large for the frame, you may trim the outer diameter of the edge as necessary.

5. Apply 1/8” bead of adhesive to flat lip on cone edge OR to underside lip of foam if cone is angle attach style. Smooth adhesive uniformly and immediately apply to cone. See figure # 3. 

6. Work new edge to cone for several minutes and allow to dry for one hour. It is easier to install new edge to the TOP of cone regardless of original location. Performance is not affected either way. See figure # 4.

7. Before gluing to frame, exercise the cone by pressing down evenly around the dust cap.  This will give you a “feel” for the  center of the assembly. Notice how the cone can easily be moved in one direction or the other slightly and the “sweet spot” where there is no scraping of the voice coil is easy to locate. See figure # 5.

8. Insert tip of adhesive bottle under new edge and apply glue around the frame.  Use your fingers to lightly press the topside of the new edge to distribute the adhesive evenly. Again, exercise the cone as shown above to center the assembly. Also place fingers above and below cone and exercise up and down as shown. Once centered, press new edge evenly around frame and  allow to dry for one hour. Wrinkling of the new edge is normal and will subside as the adhesive cures. Check new surround as required. See figure # 6.

9. Apply a 1/8” bead of adhesive to the top of the center of the new edge on the frame and replace gasket removed in step # 2 if applicable. Place the speaker gasket side down to cure for one hour. See figure # 7.

10. Reinstall speaker into cabinet noting the correct wire hook up to insure proper performance. Also make sure to re-use any seals between speaker and cabinet.

Special Repair Techniques

1. When centering Bose 901 or Bose 802 speaker drivers, it is easy to find the exact center by applying slightly more downward pressure on the side of the cone with the two lead wires attached.

2. You may repair the speakers in the Bose 901 or Bose 802 systems right in the cabinets. There is no need to remove!

3. When cleaning the underside of the masonite trim rings on original Advent and Dahlquist DQ-10, DQ-20 woofers, it is easiest to use the blade of a utility knife to cut away the old foam glue from the underside of the trim ring.  After gluing the new edge to the top of the cone, you can apply adhesive to the TOP of the new edge outer lip and then smooth uniformly. While the adhesive is wet, press the cone assembly all the way down until it stops.  Most of the new edge will pull under the masonite ring. Use the tip of the utility knife to push the rest of the surround edge under the trim ring.  Lift the assembly up and exercise the cone to proceed as shown in step # 8.

4. When working on the Acoustic Research 11” woofer in 12” frame (2 sides of frame are cut off) it is best to apply the adhesive to the underside of the inner lip of the new edge and “form the edge” to the angle of the cone as the adhesive cures.

5. When working with JBL LE-series woofers, make sure to remove the hard black plastic trim ring from the frame and save it for reuse. You can also clean the underside of these cones carefully to install the new edges in the original location IF YOU ARE A SKILLED DO IT YOURSELFER. Otherwise, install the new edges to the TOP of the cones.

6. On Pioneer HPM-series woofers be careful when cleaning the cones as the graphite cones can crack easily.

7.  When repairing Boston Acoustics A-40 with 6-7/8” frame, trim the outer diameter of the new edge to 5-13/16”.

8. If your cone is an odd size such as the 6-3/8” cone Advent 2W, Boston Acoustics HD-7 with 5-3/8” cone, and others, you may trim through the new edge and downsize by resizing to the cone diameter for gluing.  Remove all but 1/4” of the overlap and glue new edge together at the overlap.  Proceed as a normal repair outlined in the repair instructions.

9. If you are using shims for the voice coil, be sure to space them evenly in the magnetic gap. Be cautious when removing the dust caps to prevent damage to the lead wires. Do not remove shims until adhesive has cured for at least one hour.

10. If you purchased foam guard sealant, apply lightly to exposed surface of surround with a small brush. 

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