My 2002 Honda CR-V Xenarc fabrication thread

[justintime]

I'll try to keep this thread updated with progress.

Status right now: Test fitting Xenarc screen, deciding best way to make it work.

Looks like this is a very close fit that could look factory! If anyone has examples of how to shave off the sides of original Xenarc housing, please point me in the right direction.

A few pics of my findings so far... Test Fitting only!

[RS3RS]

Looks like it's going to be a nice install!

As far as the 1/8 inch, really rough grit sand paper?

[RoyN]

Dremel? But you will probably need steady hands...

[Cris]

Dremel? But you will probably need steady hands...

That's what's I thought, but if don't have steady hands, and didn't work much with the dremel, don't, you won't cut it straight, plus the size you need is way to small, so get a sandblock and use a low grit sandpaper, maby 80 grit, so you don't dig too much, but step by step. using a sandblock allows you to get a straight finish.

[justintime]

Good idea. This way I can go little by little until fit is just right (and 'tight')

How about the bottom part that I need to trim off? I think I need to dremel it first. And then sand with grit.

Also, here is a screenshot that details the placement of the housing:
click for image

That's what's I thought, but if don't have steady hands, and didn't work much with the dremel, don't, you won't cut it straight, plus the size you need is way to small, so get a sandblock and use a low grit sandpaper, maby 80 grit, so you don't dig too much, but step by step. using a sandblock allows you to get a straight finish.

[Cris]

Good idea. This way I can go little by little until fit is just right (and 'tight')

How about the bottom part that I need to trim off? I think I need to dremel it first. And then sand with grit.

Also, here is a screenshot that details the placement of the housing:
click for image

If you use a dremel, be very carrefull, as if you don't cut it straight here, you might regret it (ask me, I now that now... ). If you ask me, a very fine saw (make sure it's really tight and straight) will do the job perfectly.

[justintime]

Thanks for the pointers. I have decided to sand the Xenarc's front frame, until it fits. I will then glue it to the car's housing, and bondo/sand the 'joints', as well as paint the recessed area.

I think it sounds like a plan, should look mondo factory.

[TimmyM]

I would use a belt sander, stationary if you've got access to one. If not clamp it down and use the belt sander on it. Even a good palm sander would work. I have the Porter Cable model 333, it works great. Use about an 80grit for the palm or 120grit for the belt.

[justintime]

Should I worry about melting the plastic if I sand this thing?

[TimmyM]

possible. go slowing and lightly with the belt sander. with a palm sander you less likely to have tha problem. You might try with a peice of simular plastic. you could also try a table saw if it will lay flat. I've cut acrylic that way.