Mazda6 Dash Fab
I made this door in the dash in the place where the map pocket was. Most other people just put the screen under the map pocket door; i decided to completely fabricate a new door for the screen, it is actuated by two RC car shock absorbers that spring the door up after little effort and hold it down while closed. The door is made from fiberglass, bondo, and plexiglass.
Nice, that is probably the cleanest looking Fiberglass mazda6 map pocket installs I have seen. Makes my screen install look like crap. Kudos! Wanna redo mine? :)
Photos!! WorkLog!! Please!! I also have a Mazda 6 and will be looking to do something similar. Please give us some details!
unfortunately, I didn't take any more pictures as i was fabricating the screen mounting. If you have any questions on exactly how i did it i could do my best to describe the methods i used.
1. What size screen did you put it?
2. How did you get the shape the same as the original door?
3. Does the screen open and close by a motor or by hand?
I'm sure there are more but I can't think of them right now.
some more info on the actuators and how you wired it up would be nice. I bet lots of people would like to make moving doors. Looks good, some more detailed pics please :)
He used RC car shock absorbers so I don't think it is motorized.
I'm curious too what you used to form all the pieces? I built mine completely out of wood and covered it with vinyl that matched the dash. Yours looks so much cleaner though and looks like how I wanted mine to look.
Did you paint yours or cover it in vinyl?
It's kind of complicated but I’ll do my best to explain exactly what I did.
First I bent a piece of cardboard across the hole in the dash and taped it down with masking tape and I masked the clean dash and the cardboard with aluminum foil. I layered 6 layers of fiberglass cloth and resin over the cardboard (the foil is to keep it from sticking). now I have the rough shape of the dash, I cut it to shape. With the original map pocket I cut away the bottom of the compartment and remove the risen up area that the clasp attaches too, I used thin Plexiglas to repair the open part exposed by removing the clasp area so that it was flat instead of humped up.
The lilliput screen mounts on the back with 1 screw, I attached a thick piece of Plexiglas about 2*2 inches to the middle of a 1/4 in dia steel rod that's the length of the width of the compartment. I drilled a hole through the thick Plexiglas and screwed it to the back of the screen. So now I have a screen with a rod sticking out both sides. I drilled holes in the sides of the map pocket so that the screen can rotate in the holes and flip up and down.
I then put aluminum foil in the hole in the dash and put the map pocket back in with no bottom, I laid layers of fiberglass in the bottom of the hole to create a new bottom to the map pocket the is the full depth of the hole.
I then attached springs on either side of the screen in the back corner of the new box and to levers I welded to a 1/4in shaft collar that I placed on the 1/4 in shaft. The lever is positioned so that the spring pushes up behind the shaft holding the screen down, and when you rotate the screen a few degrees it pushes up on the other side of the shaft holding the screen up.
The fabrication of the dash is difficult to describe...but here goes...
The rough shape of the dash I made earlier is cut slightly smaller than the opening in the dash, from the font of it I cut away a rectangular section that is slightly wider than the width of the screen, and deep enough that when the screen is in the upright position it has clearance behind it. I removed the screen rod attachment from the box and covered it in aluminum foil, and layered fiberglass over the back of the screen, and cut the fiberglass to the size of the back of the screen. I attached the front of the cut out dash shaped piece to the screen shaped piece put a wooden wedge between the two pieces such that when the screen is down it matched the shape of the dash. I stretched t-shirt material between the two pieces on the sides and painted on fiberglass resin until the whole thing was rigid. At this point you should have the rough door. I took what was left of the rough dash piece to make the surround. I glued triangular shaped Plexiglas pieces to the insides of the cut away area to make the sides of the exposure when the door is up. I put everything together, keeping in mind that everything should be slightly less than flush with the dash. I then used bondo and a straight edge to flush everything up with the dash. I did a LOT of sanding with 800 grit paper, until I was satisfied with how it looked. I then painted the whole thing with black simigloss spray-paint. The last layer of paint is applied from far enough away to let the paint fall onto the assembly to give it a textured look similar to the black plastic of the radio/ac screen.
Sometime this summer i intend to do some more work on everything, in which case i'll take more pictures with it taken apart so that you can see how some of the things go together.
any chance of a diagram? And what size screen do you have? How did you cut the fiberglass so straight?
^ i'll draw one soon, 7in., and heavy duty scissors and a utility knife