Problem
Factory speakers in the 2016 Veloster Turbo are one-piece units riveted into the door. No direct-fit aftermarket adapter exists for this vehicle, and universal brackets could not accommodate the tight clearance required between the speaker magnet and the window track, as well as the gap between the speaker and the interior door panel. This required a fully custom bracket designed and printed from scratch.
Design & Iteration
The bracket was designed in SolidWorks and 3D printed in PLA on an Ender 3 S1. Two iterations were made, each installed and tested in the vehicle.
Iteration 1 — The first version served as a proof of concept to validate whether PLA could withstand the temperatures inside the door panel while out of direct sunlight. Bolt holes were slotted to provide tolerance for hand-drilled mounting holes, and hex bolts were used for fastening. After approximately three months of use, the slotted holes allowed the bracket to shift over time, causing it to come loose. The tabs also developed slight bending from the movement.
Iteration 2 (Final) — For the second version, slotted holes were replaced with standard circular holes to eliminate movement. Ribs were added to the mounting tabs to prevent the bending seen in the first version. Hex bolts were swapped for Phillips-head fasteners to match the rest of the door hardware and simplify installation and removal. This version has been installed for over a year with no issues.
Result
- Skar 6.5" components mounted securely with proper clearance
- Window operates freely — no magnet contact
- Door panel closes flush