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I believe 5¼ is what Ford was using, I'm also under the impression they have a large mounting flange and that 6½ speakers - which apparently don't have such a large flange - can fit in the hole but you'll probably need to drill new holes.
Again, this is just my understanding, I don't recall for certain. You can search the archives for more, this has been talked about before.
I just did this about a month ago on a 86. The 6.5"s fit fine in the holes. I went with sony xplod 4 way speakers from walmart for right at 50 bucks. They fit fine in the opening. Line up 1 hole and screw it in a few threads. Use a small drill bit to make a pilot hole in 3 other mounting holes. Use the factory screws and they will self tap. Mount all 4 before tightening cause you can ****-eye the speaker. These speakers fit tight against the door panel. With a good 3 or 4 way there should be a tweeter brace across the top so the woofer can move. These speakers came with a cover plate so you can trim the door panel around it and screw on the cover if you want. I doubt the sound quality will improve much but its a option.
I sure hope so; I just popped the order for 6-1/2s on your say-so.
Many years ago, when I replaced the factory speakers with RoadMaster 5-1/4" 3-ways, I had to do a bit of sheet-metal trimming then, plus drilling new holes.
These RoadMasters bulged the door-panel outward slightly, causing the window-crank to just brush the panel when working the glass up or down.
I hope the 6-1/2" Pioneer TS-A1674R that I just ordered can be fitted in the factory cut-out without too much misery/fun, depending on how one looks at it.
If push comes to shove, I will mount them in the fat area under the arm-rest/door-pull.
I would like to read/see some threads or write-ups where others have addressed this situation.
5 1/4" were usually found from the factory, but I've had newer Ford factory 6 1/2's that fit perfectly, and already had the correct mounting holes. Since then I've installed 6 1/2" woofers in place of the factory speakers and installed some factory style 6x9's in the bottom of the doors. All that work, along with an 800 watt amp and a couple of subs, the sound quality is amazing. Pretty much anything that has to do with the stereo system, speaker fitment, etc. is a "been there done that" scenario with me, lol.
You'll be alright with 6 1/2" speakers. I put them in my 86. I did have to drill new pilot holes for the screws. In my case I had to make sure to tighten down the screws evenly so the door panel didn't bulge any...
Just take your time...don't get frustrated...or you might poke your screwdriver through the speaker if you slip off a screw...I know from experience! I had to go buy another speaker because of it...You'd think an old "Led Zeppelin Man Forever" would know better, but NOOO...