Okay, last update for the night. I finally finished with the passenger side completely. It actually required a good bit of minor tweaking on the door panel and being creative with x-over placement to get it all to fit. I'm also pretty anal about stuff like this so it took me a long time to get all the wiring done. Luckily I have a comfortable garage to work in with a TV so I basically camped out on the floor all night.
Here's a pic with all of the wiring done. The x-overs are held in place with industrial Velcro. That came in handy for adjusting the position while I tried to find locations that let the door panel fit back on.
The covers to the x-overs have to stay off for clearance...it's that tight. Also, make sure to leave that little cup behind where the mid goes open. I originally had deadener over it but I found out it's actually there to give the mid enough clearance.
All connections are shrink-wrapped to keep things tidy and secure, then covered with the protective colored jackets.
Here's the woofer installed. I ditched the hardware that came with the set and picked up some more secure stuff at Lowes. I used speed nuts and 3/4" #8 screws to mount the plastic ring to the door and also ran a thin piece of weatherstrip between the door and the ring to get a nice seal. I used 1/2" #8 screws to mount the woofer to the ring (also with a layer of weatherstrip).
I had already spent way too much time working on just one door today but I didn't want to just slap the panel back on without giving it a bit of sound deadener to add some mass and hopefully avoid nasty resonance. I didn't spend a lot of time but hit most of the flat surfaces.
The only issue I have is that the door panel doesn't fit tight against the door on the lower outside corner. It's not hitting anything so the best I can figure is that the plastic clips aren't fully engaged but I've whacked it pretty good with no luck. I've got it all bolted back up for now. I'll see if I get any rattles or buzzing before I pull it apart and make an attempt to fix it.
So I've only listened for about 30 sec but honestly, it sounds stock, if that. I've got the mid set up +3db and the tweeter set to "reference". The woofer doesn't seem to have as much punch as the stock stuff in the driver side. Now keep in mind that I'm only using the power coming from my RNS 510 and haven't done any tweaking with the sound settings...or even given them a chance at all really. I was tired of living in the garage and really just wanted to make sure everything worked before shutting things down for the night. Hopefully I'll get the driver side done in the next few nights.