Instructions

STEP ONE: REMOVE WOOFER FROM CABINET. Select the proper screwdriver and remove woofer from the front. Take care not to accidently puncture the cone when removing the screws. Before disconnecting the wires, observe the polarity of each wire and label. It is very important to re-connect the wires with correct polarity. If the wires require desoldering, be sure not to over heat the terminals.

STEP TWO: REMOVE GASKET MATERIAL. If the speaker is equipped with a cork or paper surround, it must be removed. Carefully insert a sharp utility knife between the gasket and the old surround. Slowly work your way around the gasket. Prying it off until the original glue seam is broken. If the gasket becomes delaminated during disassembly, you can repair it with the enclosed glue after removal. Note gasket placement on basket. (If there is no front-mount gasket, skip to Step 3)

STEP THREE: REMOVE THE OLD FOAM FROM BASKET. Carefully remove the old foam by scraping with a utility knife around the basket. Clean down to the paint or metal basket surface. Try to create as smooth a surface as possible. Wipe the entire basket rim clean with a rag moistened in isopropyl alcohol.

STEP FOUR: REMOVE OLD FOAM FROM THE CONE. Pull the old foam from the cone, making sure not to damage the cone. Use your fingers to rub off the remaining foam particles from the cone's edge. Remove as much foam as you can, but leaving a thin layer is acceptable.

STEP FIVE: REMOVE OLD DUST CAP FROM CONE. (NOT FOR BOSE 901/802!) Using a sharp utility knife, slowly cut an "X" into the center of the dust cap and peel it back. To remove the dust cap, carefully cut around the edge of the cap taking care not to cut the voice coil, lead wires and speaker cone. Note: Do not cut into the cone to remove the ridge where the cone and dust cap meet. Leaving a small ridge around the cone is acceptable, this ridge will be concealed when you install the new dust cap. Be careful to avoid getting dust and debris in the voice coil area while removing the dust cap.

STEP SIX: ALIGN ASSEMBLY. (NOT FOR BOSE 901/802!) Insert three voice coil shims lengthwise into the space between the voice coil former and the center metal pole piece. Space the shims at 12, 4 and 8 o'clock positions. Note: These shims help maintain proper voice coil alignment with the center pole piece while installing the new foam surround. Included in this kit are two pairs of different style foam surrounds (6-1/2" & 15" kit include only one pair). The difference between the two types of surounds is the gluing edge. Choose the foam surround pair that is most compatible with your speakers. Place the new foam in position. Be sure to carefully test the surrounds with the gasket in place before you begin the gluing procedure outlined in Step Seven. Note: If the original surround was attached to the rear of the cone, push surround over cone and adhere to rear.

STEP SEVEN: GLUE SURROUND TO CONE. Apply glue to the cone edge and spread evenly with a foam swab. Make sure not to let glue drip down cone surface. Now apply a coat of glue to the inside edge of the foam surround and spread evenly. Allow surfaces to cure for approximately 5 minutes until they become almost transparent and tacky. Lightly place the new foam on the cone, matching the glued surfaces and making certain the surround is centered on the cone. Press around the cone edge to adhere surround to cone. Smooth out any ripples or lumps. Take your time and work slowly to achieve the best results. Allow surfaces to bond for at least 1 hour before proceeding to Step Eight. Glue will not bond if it is still wet.

STEP EIGHT: GLUE SURROUND EDGE TO BASKET. Apply a thin bead of glue to the bottom of the surround edge. Also apply a thin bead to the frame surface. Evenly spread both surfaces with a uniform, thin coat using a foam swab. Allow glue to cure for approximately 5 minutes. Before attaching the surround to the basket edge, gently and evenly lift the cone until the outer edge of the cone is even or slightly higher than the basket edge. Note: The voice coil shims should help maintain this cone position. Lightly press down on the outer edge of the foam surround and work around to bond it to the basket edge. Allow surfaces to bond for at least 5 minutes before proceeding to Step Nine.

STEP NINE: REATTACH GASKET. (NOT FOR BOSE 901/802!) Clean off old glue from gasket and create a flat, smooth surface. Apply a thin layer of glue to the gasket and top of surround. Spread evenly with a foam swab and allow to cure for approximately 5 minutes. Refit the gasket material as it was originally positioned. Turn speaker over (gasket side down) and press on table to bond gasket to basket/surround assembly. Allow to cure overnight before proceeding to Step Ten.

STEP TEN: REATTACH DUST CAP. (NOT FOR BOSE 901/802!) Carefully remove the three voice coil shims. Using a foam swab, apply a thin layer of glue to the rim of the dust cap. Center and gently place the dust cap over the voice coil. Note: If you're installing the poly dust cap to a poly cone, for best results, use a gel type super glue (Parts Express #340-620, optional). Allow the dust cap to bond for at least 1 hour before reinstalling into cabinet or testing.