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Custom Aluminum Overhead Console (Pics inside)

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  • Custom Aluminum Overhead Console (Pics inside)

    The purpose of the overhead console is 3 things:
    - House a character display (which will be used for displaying track titles, the temperature, etc)
    - Hold my glasses (I only need them when I drive..so when I leave my truck, I leave em on the arm rest..and they keep getting knocked over)
    - Power switches and LEDs (for the computer, inverter, and monitor)

    Now, onto the pictures

    First, I had to drop the headliner to take a mold of it. I need to get the shape of the headliner, and the easiest way that I know of is with fiberglass.



    The wire hanging down in the 2nd picture goes from the computer (for power, reset, HDD LED, etc) to what will be the OHC.
    Also, if you look closely in the 2nd picture, you can see the aluminum bezel I made (by hand) for the H/U and DVD drive. I'll eventually post more pictures of that in my progress thread (link in sig)
    Attached Files
    Take 2 - '03 Audi A4
    macmini with an 8" widescreen (in progress)

    My 2004 Ford Ranger:
    14" LCD w/ custom made aluminum bezel
    Completly custom computer case

    status: Totaled

  • #2
    Here's the mold

    And the 3rd and 4th pics are of the roof of the truck. I took pictures so I have an idea of what the mounting bracket for the OHC will look like.
    Attached Files
    Take 2 - '03 Audi A4
    macmini with an 8" widescreen (in progress)

    My 2004 Ford Ranger:
    14" LCD w/ custom made aluminum bezel
    Completly custom computer case

    status: Totaled

    Comment


    • #3
      Heres the beginning stages of the console. I'm positioning everything and clamping it up to be welded.

      I had the sides cut (with the top shaped to the curve of the headliner) and all the bends are done. I also made the bottom piece for it.

      The 2 small pieces going across the front and back were just to keep the width while making the bottom piece. They get cut off later.
      Attached Files
      Take 2 - '03 Audi A4
      macmini with an 8" widescreen (in progress)

      My 2004 Ford Ranger:
      14" LCD w/ custom made aluminum bezel
      Completly custom computer case

      status: Totaled

      Comment


      • #4
        Here it is with the inside welded, and the excess metal cut.
        Attached Files
        Take 2 - '03 Audi A4
        macmini with an 8" widescreen (in progress)

        My 2004 Ford Ranger:
        14" LCD w/ custom made aluminum bezel
        Completly custom computer case

        status: Totaled

        Comment


        • #5
          look alright sofar
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          • #6
            Here it is with the top welded, and grinded.

            Problem #1: The lip I was going to put the character display on had to be cut shorter because it was blocking my rear view mirror. After doing alittle bit of searching on google, I found that almost none of the character displays I looked on would have fit in that lip. So, unfortunatly, there was no sense in leaving it. Which explains the cut across it.
            Attached Files
            Take 2 - '03 Audi A4
            macmini with an 8" widescreen (in progress)

            My 2004 Ford Ranger:
            14" LCD w/ custom made aluminum bezel
            Completly custom computer case

            status: Totaled

            Comment


            • #7
              I got too caught up in working and stopped taking pictures for a bit. I did a couple things here:

              - I cut the front, welded it, and grinded it. Then added the back piece.

              - I then started on the cutout for where the glasses holder will go.
              Attached Files
              Take 2 - '03 Audi A4
              macmini with an 8" widescreen (in progress)

              My 2004 Ford Ranger:
              14" LCD w/ custom made aluminum bezel
              Completly custom computer case

              status: Totaled

              Comment


              • #8
                Right now, I already have the glasses holder complete. I'm just working around the problems that I've run into, and still coming up with a way to hing the holder to the OHC.

                I might update the pictures tomorrow, but I won't be working on it much until monday.

                I'm just a bit disappointed that I won't be able to add the character display. But at least if I find one small enough, it really won't be that much work to weld up a new house for the display, and weld it to the OHC.
                Take 2 - '03 Audi A4
                macmini with an 8" widescreen (in progress)

                My 2004 Ford Ranger:
                14" LCD w/ custom made aluminum bezel
                Completly custom computer case

                status: Totaled

                Comment


                • #9
                  looks great, i gotta learn how to weld!

                  how small of a character display do you need? did you check out matrix orbital?
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                  • #10
                    Originally posted by scott_fx
                    looks great, i gotta learn how to weld!

                    how small of a character display do you need? did you check out matrix orbital?
                    Thanks. I just HATE working with fiberglass, so for me..welding/metal fabrication is the way to go.

                    I think that's one of the sites I looked at. That lip (before it was cut) was around 1/2 inch. I found displays that had the viewable area 1/2 inch, but the overall size of the unit (heigh wise) was just too big.

                    I was originally hoping to put a 2x20 in, but now, I'm thinking that maybe I might be able to squeeze in a 1x16 in a different location then it was before (out of the way of the rear view mirror)
                    Take 2 - '03 Audi A4
                    macmini with an 8" widescreen (in progress)

                    My 2004 Ford Ranger:
                    14" LCD w/ custom made aluminum bezel
                    Completly custom computer case

                    status: Totaled

                    Comment


                    • #11
                      lookin good. i want to do an over head in my car, but i don't know how to weld, and i've never used fiberglass

                      keep it up man!

                      Comment


                      • #12
                        i made one out of fiberglas a little while back
                        its pretty easy to use
                        so is tiggin' if u got the right exipment
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                        Comment


                        • #13
                          Here's the next round of updates..

                          The first picture is of the mount that I fabricated for it.

                          The others are of the hole i made in the headliner, and you can also see the second part of the mount, which is a piece of steel bent to the countour of the roof. That piece is screwed into place, and then i drilled and tapped holes for the mount (in the first picture) to screw into. The benefit to all this is that it's easily removable, and it's just a really solid mount.

                          On a side note: I read somewhere that someone said cutting into their headliner was a real pain. I can't understand why they thought this, as I had absolutly no problem cutting mine. I used a utility knife for carpet to cut into the headliner..for anyone doing a project like this, I would suggest investing in one.
                          Attached Files
                          Take 2 - '03 Audi A4
                          macmini with an 8" widescreen (in progress)

                          My 2004 Ford Ranger:
                          14" LCD w/ custom made aluminum bezel
                          Completly custom computer case

                          status: Totaled

                          Comment


                          • #14
                            This is a shot of the hinge I made for it..but mostly these pictures just show the inside of the door, where my glasses will go.

                            I had to make a hinge because I couldn't find one that would allow it to work properly..the door has to not only swing down, but swing down and foreward to clear completly.

                            Note: after adding cabinet stops to keep it shut, I decided that the hinge works like crap. There was just too much play in it, which meant the door was always getting jammed. I decided to use my very first idea, which meant that the hinge would be partly visable from the outside (which is what I was trying to avoid). I already have the new hinge and stops done, but no pictures yet.
                            Attached Files
                            Take 2 - '03 Audi A4
                            macmini with an 8" widescreen (in progress)

                            My 2004 Ford Ranger:
                            14" LCD w/ custom made aluminum bezel
                            Completly custom computer case

                            status: Totaled

                            Comment


                            • #15
                              Here's the mount screwed into place.

                              The wires hanging down go to the computer (for power, reset, etc), the monitor, and the inverter.

                              Right now, I have the inside of the glasses part felted, and the whole unit is mounted, with a much better hinging system (it looks alot cleaner without the complicated hinge too). I'll post thoes pictures in my next set.
                              Attached Files
                              Take 2 - '03 Audi A4
                              macmini with an 8" widescreen (in progress)

                              My 2004 Ford Ranger:
                              14" LCD w/ custom made aluminum bezel
                              Completly custom computer case

                              status: Totaled

                              Comment

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