On the fairing, I opened up the speaker holes with a rotozip so I could get theInfinty's in. They still extended slightly over and under the fairing base. I tried to center them as much as possible. I have had them in for quite a while. I think I have had them in for over 2 years. When I installed the meter cover over them, it made the cover bulge downwards slightly just under the grilles. It was a tight fit and I just ignored it.
What happened was that on the left side, I developed a large crack from the base of the grille all the way down to the vent.
One thing I noticed was that the meter panel is pretty thick and I think that I could easily grind away enough material where the speakers bind to make the panel fit much better. I may try that with this old one to see how it goes. I like having the larger speakers. If that doesn't do the job, I have 2 other options in mind.
One is to pick up some larger ABS panels, and glue/attach them over the enlarged area and go back to the original 4.5" hole which I don't think would be a problem. I have a 4.5" hole saw and experimented in drilling the holes in 1/8" plexiglass. As long as I took my time, I was able to make the holes without causing the smaler plexiglass panel to crack. (I guess I could just use the plexiglass cut to size but Imnot sure how it would hold up) The mounting point on the fairing is still solid and patch pieces, I'm sure, would work rather nicely. This would alow me to switch over to the Polk BB501 speakers.
The second option is to fab some kind of face plate to mount just in front of the grilles, remove the grilles, and keep the 5.25" Infinity's. I have been researching other plastic panels like plastic/acrylic. I came across this youtube video that shows how to do your own bending: http://www.youtube.com/watch?v=ovqnIBQuezA
and I can build my own bender. The element is available here
. There is, I believe enough room in front of the grille to build a plastic enclosure big enough to easily house a 5.25" speaker mount without blocking the vent. And I would also increase the mounting depth. I'm not sure if I am abmbitious enough right now to undertake that right now though.
Decisions, decisions.... But the first step is tofind a fresh meter panel cover and go from there.