Thread: First Steps - Custom Screen Mount in 200SX

Right folks, I've finally taken the plunge and started doing a proper fabrication job for CarPC v2

I'm going the ABS/Acetone method And I must say, so far, this is the easiest, albeit timeconsuming method of making a custom bezel for someone who is no good at using body filler/bondo. Just be careful to ware some decent (IIRC Nitrile) gloves cause the stuff is a ***** to get off your hands, especially when mixed very thinly. Also be sure to be in a well ventilated area unless you wanna get pie eye'd

I don't know why I was having so much trouble melting the dash last night cause its all gone like a dream tonight.

I have taken some pictures of what I have done this week. Im doing it slowly but surely as mistakes take even longer to sort out There are also some pictures of the tackle I used, and my ABS pellets (with Cig box on as size reference).
The front bezel of the screen is being moulded straight to the dash trim and then re-assembled so it becomes part of the clip on panel. I have chosen to mount the screen in this particular panel as the heater controls can be located in to the lower DIN slot. And this panel is high in the dash, easy to reach and has zero glare as it reflect stright off the roof liner and not a window! And it is only held in with metal snap clips, so it effectively makes my screen removable (for security). I will be locating the vents further up/back on the dash by choping a hole in the dash top (with my trusty Dreme) re-ducting the air flow, and using vents from another car, probably a Peugeot 407 as they are set on quite a shallow angle so the don't just blow at the roof.

I've cut my dash panel to the rough shape I need with my new Cordless Dremel, and stuck the lilli in with just a few small blobs of ABS where it contacted the dash panel. Once they had hardened, I then started using some thick black (IIRC roofing tape, like Duct tape/Elephant tape) tape to create a mould, then just slowly poor in the ABS. Oh yeh, before I forget, I made a fake screen unit from MDF board so the lilli bezel doen't deform whilst it's still soft.

I got the Acetone from Dulux Decorators Centre in Rochdale, and the ABS Pellets from my local injection moulding firm. Can't tell you their name as my contact doesn't want to get in trouble for giving away stock

For those who can't find a decent container for the ABS gunk I've found that a Zefal bicycle drinking bottle is perfect for the job, sold at any bike shop or Halfrauds. You can also use most aerosol can lids to mix small quantities.
Hair drier is used to gently warm the mix so it sets a little faster, it also comes in handy to stop runs. Don't get too close or get it too hot though as it bubbles up

To get to this stage has probably taken me about 3 hours, but I did say Im taking my time...


Anyway, now for the pics.