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Here is a picture of the old rear surrounds. Polk Audio FX I300s.

Here is a picture of the new Surrounds I built with GR Research Drivers.

My first step, after building the speakers, was to determine where my speakers were going to be installed. When measuring my layout, I was fortunate that my stud walls where in exact locations in relationship to the opposing wall. So they are exactly across from each other.

After establishing my layout, it was time to do some cutting!!! Again, my speakers are the exact width of the space in-between the studs, so they should fit nicely. On this side, my opening for this speaker goes into an adjoining unfinished closet. On the other side, behind the finished wall is the concrete block wall.

Here is the finished rough opening awaiting the new speaker enclosure.

Now it is time for the moment of truth. The trial fit!!! And it fits like a glove!!! Great!! Now, it is time to install the drivers and fire up the amps!!

Here are some pictures of the semi-finished product!! I am very please with the way they turned out. The only thing I have left are the grills and they will be done. My favorite feature of these speakers is they sound great, perform well, and they don't stick out at all. This way, the people I have over, don't bonk their heads on the surrounds when they walk down the aisle. 
 
 

Phase 2: Grills

  

When designing the grills I decided to leave about an inch over hang around the speaker enclosure. After marking out the layout on the blank grill, it was off to the router table. I routed out the appropriate spaces and used a round over bit on the front and back of the grill openings.

I had to get my mug shot in there somewhere!!!
One thing I like to do, is spray paint the front and back of my grills. This way when you wrap them in grill cloth the raw material color doesn't show through.
After wrapping them in grill cloth it was time to head to the theater and test them out. The work like a champ and now the aisles are free of obstruction.
 

Thanks for checking it out!!! And stay tuned for the grills!!! 

Thanks,

Shawn Keeler