Posted by: willtblog | April 13, 2010

Update #9: Paint + Cutting

So, Scratch that when I said the fit wont be flush. I borrowed a dremal tool from a mate, and made it fit. Looks muuuch better!

Flush!

Flush

I then sanded the fiberglass down, and started to paint it. I used some hi-tep black spray paint because thats all I had in the house.

First Layer

Shows the imperfections! :/

Its ok.

Now I had finished (to an extent) the front side of the relocation, I need to make way for the wires at the back. This was a simple job with the Dremal.

Cut.

Fits!

Flush Finish

After a bit of a clean, I have this:

Looking good, But no where near perfect :/

With faceplate in

With faceplate in

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Posted by: willtblog | April 12, 2010

Update #8: FiberGlass Pt3

So, The front came out nicely, and the edges have finished drying. I plan to cut the excess off, sand it down and cut the hole for the A/C unit today. Pics:

Side layer 2 complete

Looking good, but not perfect :/

Clearence is about 5mm each side at the thinnist point

WiP

Blured due to dad taking the photo 😛

Not flush.........................

The A/C pannel will not be flush like I planned it to be. This is due to technical limitations and my limited skill with FiberGlass. This is my firstime working with the stuff. So this would be a thing I can improve at a later date.

Posted by: willtblog | April 11, 2010

Update #7: Fiber Glass Pt2

Today I sanded down the first layer of fiber glass and made sure the fit was ok. Yesterday there were a few problems, the mold ‘swiveled’ while inside the Ash Tray compartment. I figured out why; the bottom of the mold extended out too much. I chopped it off using my handy bread knife (Which cuts fiber glass pretty well also!).

A few more pics:

Sanded

Sanded

As I needed to get the front perfectly flat, I thought of two ways I could achieve this.

The first, is the most painfull and requires a lot of sanding. The second seems much easier.

The Epoxy glue that I am using ‘peels’ off of plastic. Why not use a long flat piece of plastic to rest the wet epoxy on? Thats exactly what I did.

The unflat mold

Hopefully this will work.

Flat box

UPDATE:

The fiberglass has now dried at the bottom, and came out perfectly flat (Y). I added another layer of fiberglass around the mold. Pics:

It worked (Y)

Flat!

Layer 2

Posted by: willtblog | April 10, 2010

Update #6: Fiber Glass

I have managed to get some fiber glass and have started to fiberglass the mold! I have just done the sides, and will do the front side tomorrow.

Equipment

Close Up

Painting it on..

Edges done.

Posted by: willtblog | April 9, 2010

Update #5: Mold

So, I have made two mouds, the first was crap, due to my impatience. So I created another. The second one is much better. See pics.

Mold 1

Mold 2

I plan to chop the foam to the correct angle (For the mounting of the A/C controls). Fiber Glass the exterior, sand, Fiber Glass again. Then sand, primer, sand, primer, and paint!

I have also cut the mold to shape, And fits pretty well!

Bread Knifes are made to cut expanding foam!

A great fit

Flush..

Now to aquire the fiberglass.

Posted by: willtblog | April 8, 2010

Info: AU-650 XR-7V401 Stereo

I have been a little paranoid to take my stereo out of the car due to a few people on the forums. They said that the radio once disconnected from the battery would ask for a key code (Anti theft device). After gaining a bit of courage, and realizing what I had to loose (After I blew the cd changer up, I only could listen to One radio station to the band expander not working..) I disconnected the stereo!

There is no anti-theft code of any sort on the AU-650 found in the 1997 Audi A4 Quattro! (Although you cant blame me if yours asks for one lol)

A few pics and a wiring diagram:

Pin-out for the AU-650

Front

Back

Connections

Aerial Plug Location (*dashboard :P)

Posted by: willtblog | April 8, 2010

Update #4: CarPC Parts

The foam is still setting (3 hours later), must be because I put a load in there.. Ill leave it until tomorrow. I have just been looking at the parts I need to get in order to get a fully functioning CarPC. As I have already purchased my 8″ Lilliput Touchscreen, I have yet to get the remaining parts.

My Ideal Setup Below:

Total: $1026

And that is just for the CarPC itself, When I get these parts there will still be no audible muzic! :0

After I get all them parts, I need to get an Amplifier.

I like the Alpine PDX range, I will need the PDX 4.100 for my speakers, and a PDX 1.600 for my sub(s) (Mabye the PDX 1.1000).
The amps retail at $550 + $550, thats already $1100 USD without any decent speakers. Add that to my current price, and its a hell of a lot.

I am looking for a cheaper alternative, but my pc specs will stay as listed I think, I even may need to get some more hours at Foodtown.

Posted by: willtblog | April 8, 2010

Update #3: A/C Mould

As I see it, there are two ways that I can mount the A/C Unit in the Ash Tray compartment 1. Source some ABS plastic sheets and cut it out or 2. Fill the Ash Tray Compartment with expanding foam, and cut it into shape.

As I have no idea where I can get some ABS plastic, I have progressed with the Expanding Foam idea.

I bought some electric tape + some expanding foam from Mitre 10.

No More Gaps! + Tape

No More Gaps! + Tape

Because the expanding foam fixes itself to almost anything, I taped the inside of the Ash Tray compartment, making sure there was no plastic visible!

No plastic visible!

I then went into the workshop to spray the exapnding foam into out ash tray mould.

Start at the back and..

work your way out!

This expanding foam sets in about 4 hours. Time to make a cuppa tea and watch a film or two. I was too nervous to leave it be, and checked on it every 5 mins.

5 mins

7 mins

10 mins

15 mins

20 mins

Posted by: willtblog | April 7, 2010

Update #2: Air-Con Unit Disassembly

In order to fit the unit in the ash tray compartment, brrman removed it from the box and custom mounted it in the ash tray compartment. He said:

“This had to be the most frustrating and difficult aspect of the interior modifications. First I removed the ashtray – it is not hard once the A/C control box is removed. The A/C unit is enclosed in a box, and would not fit in the ash tray area. Hmm. So let’s remove it from the box. Now it consists of a faceplate with a ribbon cable to a circuit board containing the rear connections. Going to be tight, but I think it will go.

Next, build the faceplate that will replace the ashtray and holt the A/C controls. This was insanely difficult for me. I am no master at car modifications or stereo installations so what I did was cut out a square piece of cardboard and shaped it bit by bit as it slowly took on the form that would fit in the ash try position. Finally I got it fairly suitable and then used that as a template for cutting out the ABS plastic version. The plastic version was not perfect so I added bondo to the edges, sanded, etc to fix the defects in the shape.

Don’t forget you have to cut out the rectangle in this plastic piece to accommodate the A/C controls. This is where I lost my cool several times. The cut out is so tight near the bottom corners that there is barely 1/8 an inch left to the faceplate. While putting the finishing touches on the faceplate (ie. sanding) I broke it. After cussing a massive string of expletives (I had worked all evening to get this far) I went to work on a second faceplate. I broke that one too. I nearly exploded. Sat down with a beer and told myself I would do another one tomorrow.

A week later I had the third faceplate done, but I had a slight crack where all the others had broken. I was getting no love from above. It did not matter anyhow. I primed and painted the faceplate and then epoxied the faceplate to the A/C front panel. FINALLY.

Wait – “How does the faceplate stay secure in the ashtray position?” you ask. I used a series of plastic tabs glued on the bottom of the unit so that it would hook into holes I had drilled into the console. Then one more tab on the top (one that was not too tight so that I could remove the unit with a little force). The circuit board containing the plug wiring is simply laid in the back behind the face.”

SOURCE

So armed with this information, I began disassembling the Air-Con Unit.

After undoing the 3 screws on the exterior

Lift the catches (circled) and push the circuit out from behind

The Circuit

The Circuit

Now with that disassembled, I tried it for fitting, and it wasnt too bad!

I have to wait until tomorrow to get some ABS plastic, or plastic that will match the textured plastic on the Center Console.

Test Fitting

Posted by: willtblog | April 7, 2010

Update #1: Out With the Center Console!

I will start posting my updates in a new Update category.

Today I ordered my 8″ Lilliput Screen 869GL-80NP/C for $351 NZD off of Ebay. I hope to receive this sometime next week and start my dash fabrication!

I also removed all of the center console dash area so I can start to relocate the AirCon Controls. I am relocating them down to where the ashtray [was] is. This apparently is not the first time it has been done, see here for a pic from brrman at http://www.mp3car.com.

I started with removing the surrounding faceplate to expose some bolts, and the AirCon Control removal screws.

Face Plate Removed

I disconnected the cables at the back of the AirCon Control unit, and proceeded to remove the ash tray piece. Be brave with this, as it feels as if it will snap any minute! There is also a wire you will need to disconnect at the back of the ash tray.

Pull in these handy holes

The removed AshTray

Next, there are several screws that need to be undone. They are:

  1. In the left footwell underneath a cover (Use a flathead screwdriver to remove)
  2. Each side of the CenterConsole, just after the gear stick
  3. Under neath the compartment behind the handbrake (Where the OBDII port is found)
  4. 4 screws on the main panel

Pics:

1

2 (Found either side)

3 (Bad photo!)

4

Now, you need to fiddle! Yes, thats all the screws done, now pull, push and do what ever it takes to get the damn thing out, I’m sure theres a nack, but Ive not figured it yet!

REMOVED:

What a mess!

It will be worth it in the end!

Now that I have the center console out, A few more photos of it:

The Center Console

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