Thread: My Mazda3 Fab of Shame

everyone makes mistakes, as long as you learn from them its all good.

I've never been a big fan of foam unless you're making a mold especially when you have a lot of straight edges, so I personally would have gone a different route with what you're trying to do.

IF IT WERE MY PROJECT, and I wouldn't be using the the factory screen housing (attached a pic, brown stuff is the fiberboard and red is what you'll have to bondo):

1. I'd sand, scrape, or pull all the foam off.
2. I'd make some paper templates of a frame for the screen, I'd use 4 (top, bottom, left right). try to make the sides match the bezel curve as much as possible. spend a lot of time to get the templates just right.
3. take those perfected templates and trace them onto fiberboard or MDF if you have access to thin stuff, I'd use 1/4".
4. with the screen postioned, I'd tack up the fiberboard frame templates so they hold their own position and then further reinforce them (supports, glue, etc...). since they would likely be at angles, I'd take your leftover foam and fill in the backs, just make sure the excess foam has room to escape so things don't warp.
5. sand down excess foam and any sharp edges.
6. use regualar bondo to fill in gaps, seams, and imperfections, repeat as much as needed.
7. prime and use a texture spray on the bezel to get a nice look that'll match the rest of the interior.

I like this route becuase with the template approach you have complete control over straight edges and can get your frame right up to the edges of the screen for a nice clean OEM look, and you don't have to permanatly attach your screen. it can be a ***** to get straight edges with reinforced filler when you have so much ground to cover as it looks like you have to do with that kit.

just my .02, maybe someone who uses foam more can give you another fix besides starting over

At least you're trying...when I saw the metra kit I realized I didnt want to match the texture/curve, so what I did was push the screen in to the little tab parts (about half an inch in), and cut a piece of black ABS to use as a bezel...sanded it to fit the inside of the dash kit. No filler. It did leave some gaps, but people comment on how nice it looks.

Good luck with the rest of your fab, look forward to seeing how it comes out

you may not have put enough hardener and it's probably too cold. just give it some time. i dont htink i'd bring it indoors unless you have proper ventilation...which you probably dont :-)

don't forget, the time they say for it to dry is in something like 70, 75 degree weather... I wouldn't worry about it