I have a 99 tahoe and the doors have a very shallow mounting depth. rear is 2.15 and the front is 2.4. I have cdt audio 6.5 in. drivers I want to put in the factory location. Their mounting depth is, rear 2 13/16 and front 2 7/8. I can't cut out the metal backing to make room because the window motor is located there. It looks like I am going to have to surface mount them and put a .5 to .75 in. spacer between the speaker and mounting surface just so they can clear. This will leave me not being able to put the factory speaker covers back on. Now I have a 1 ft. by 7 in. area that is not covered and is an eyesore. Any suggestions on how to dress this mess up.
If you're ambitious you could try to make some fiberglass mounts. Is that an option for you?
I don't know much about fiber glass but I worked in a body shop for 9 months so I have some ability. I would give it a shot if I would look good. Got any suggestions about fiberglass mounts. what they should look like how to make them, and all that good stuff.
Try these:
https://chris.pfharlock.com/glass
https://web.njit.edu/~cas1383/proj/main/
I believe the first link shows how to make sub enclosures (in depth) and the second actually shows a few different types of enclosures, including kick panels. I'm actually in the process of making (almost done) a couple of sub enclosures myself, and these have been invaluable. For you, the most important thing will be the carpeting. Here's a link that goes into several things about making sub boxes, including carpeting.
https://www.eatel.net/~amptech/elecdisc/carpetenclosure.htm
Be sure to check this guy's section on fiberglassing as well.
With these links, you should be able to whip up a couple of kickpanels in no time, especially with your previous autobody experience. Good luck!