2003 VW GTI Worklog!

pogitalonx · 09-05-2006, 12:41 PM

Yet another GTI project! I've been reading the forums for quite awhile now and I've started building a bezel for a lilliput 629. I really really liked reading kbyrd's worklog so I'm trying to make mine similar to his. I'll be posting the first few days of my worklog soon and then the more I do the more I'll post. I've never done this before (yes, I am a fabrication n00b) so if I'm doing something wrong feel free to yell at me. I've tried reading the forums extensively so I'll be on top of things, but I've run into some snags. Anyway, here's worklog day 1!

Worklog Day 1

Hello! I have a 2003 Volkswagen GTI 1.8T, 5-speed, in Silverstone Gray. My goal is to integrate a computer navigation/mp3 player into my dashboard. Currently I have the stock monsoon system.

I want it to go from this:

To this:

(judoGTI's wonderful install. I will build my own bezel.)

Fabrication wise, I'm going to build a custom bezel out of wood/resin/epoxy/fiberglass and a replacement LCD bezel. I'm still experimenting on how I am going to do this. I would like it to be reproducable w/ some casting resin and a mold so that I can give it to others as well (they can mount the LCD inside themselves and paint it).</p>

Here's what I have "collected" so far:

7" Lilliput 629 Touch Screen LCD w/ extra bezel
M2-ATX 160 Watt Power Supply
Parts to build a monsoon-integration box(+5/6V on inputs)
Replacement Radio Cage for MKIV
Monsoon wire harness
1ghz Athlon Thunderbird (might replace later with a VIA EPIA...)

I also have a tv tuner/radio card that I'm planning on using my radio with. I'm still researching/reading about how to connect my antenna to this. For software, I really really like StreetDeck but its so expensive that I might stick with RoadRunner. I also have a USB GPS on the way that will hopefully work with FreeDrive. I already got the "maps" for my area. Any other software suggestions?

pogitalonx · 09-05-2006, 12:47 PM

Worklog Day 2

So I've accumulated more parts! Here's whats new:

Amp wiring kit to wire the M2-ATX
Remaining parts for monsoon-pc box
Epoxy, black paint and wood!
12v wire tap for lilliput power adapter
Sandpaper..

Only few things I can think of are tools and VGA/USB extenders. Perhaps some thicker gauge wire to run extra power around incase I need it.

So while I was waiting for my Lilliput screen and extra bezel, I went ahead and built a wood frame to see what it would look like in my radio cage. Here's a picture of that:

I also added little tabs on the back side of the bezel to make it fit into a groove that the radio cage has. Here's a picture of the tabs and what it looks like inside the cage.

The yellow stuff is Aliphatic Resin (aka wood glue by GreatPlanes...used in RC plane building. Good stuff. Also easily sandable)

So finally I got my lilliput in. Here's a picture of the box and a picture of the replacement bezel.

I got a little excited and decided to test fit the bezel. Looks like it is a bit too tall and a bit too narrow. If I added a bit on the sides and chopped the bottom off, it still wouldn't look right because the screen wouldnt be centered in the frame, so I chopped a lot of the bottom off and added some extra wood on the sides. I didn't get a clear shot of this but here's a shot of the wood glued to the side of the bezel.

Now I got some epoxy (the stuff you mix together) and some black paint. I dabbed some and put it inside these little cups and stirred until solid, then started sloppily filling in the voids between the bezel and the wood. Here's a picture of where I'm at right now:

I'm gonna finish this off and let it dry for a day, then come back and sand it.

pogitalonx · 09-05-2006, 12:50 PM

Worklog Day 3

Last night I hooked up my touch screen and got all the software working. It is amazing how much free software there is. I am debating on whether I want to spend 199 on StreetDeck when free software such as RoadRunner does such a great job. On my website http://www.pogi.org/ there is a youtube video of it.

So I started sanding my bezel, which isnt turning out too great. I think the epoxy isnt very sandable and its flaking everywhere. I'm going to buy some bondo and black primer to try to get it to be more smooth. Hopefully that works out better than this. It is going to be a lot of work...

RedGTiVR6 · 09-05-2006, 12:52 PM

Sorry to hear about the epoxy. Did you happen to roughen up the surface of the bezel before applying the epoxy? If not, that could be one reason it's doing what it's doing.

If you don't do this when you apply the bondo, you'll have a similar issue.

Also, what kind of epoxy did you use? Was is plastic epoxy?

pogitalonx · 09-05-2006, 12:53 PM

Worklog Day 4

Today I started really sanding the bezel. The epoxy I used is not as hard as I thought it would be, even after 36 hours of curing. After a bit of sanding the epoxy here's what it looked like:

I went ahead and bought some black primer and some bondo spot putty. So far its been working excellent. After using some primer and sanding some more here's what it looked like:

I re-measured the monsoon height and began cutting the bottom of the original bezel off using an exacto knife with saw attachment. It was taking a really long time and I started to get sloppy and ended up jabbing my finger pretty deep. After 20 minutes with the exacto knife I got only an inch deep on the bezel. Here's a picture of my hurt finger and the small amount of cutting I did:

I got frustrated with that damned exacto knife so I bought myself a dremel.

All I have left on the bezel is fabricating a way to make it stay in the dash and creating a very smooth fine finish on it. Here's a picture of the almost-completed test fit.

Looking much better now.

pogitalonx · 09-05-2006, 12:56 PM

Quote:

Sorry to hear about the epoxy. Did you happen to roughen up the surface of the bezel before applying the epoxy? If not, that could be one reason it's doing what it's doing.

If you don't do this when you apply the bondo, you'll have a similar issue.

Also, what kind of epoxy did you use? Was is plastic epoxy?

It was some kindof gel epoxy my GF had. I didnt really check to see if it was sandable. I mixed it with some acrylic paint and it was really gooey/gummy. I peeled most of it off, sanded it, then started with the bondo. It looks great now. I'm finished posting until later tonight when I (hopefully) finish the bezel and mount the monitor. I still have to figure out how to affix it to the radio cage. Perhaps some hot glue...

pogitalonx · 09-06-2006, 01:19 AM

Worklog Day 5

School started today so I don't have very much time to work on the bezel. Here's a picture of its just-about-finished state. All I need to do now is paint it the final color and clearcoat over it for protection.

I decided to test fit the LCD screen inside of the bezel and radio cage. Fits pretty well. Here's a pic:

I think I'm done for the night. Tomorrow I shall figure out how to mount the LCD's PCB and the Bezel to the radio cage.

phat8186 · 11-04-2007, 08:09 PM

this project is so freakin hot, since i just purchased a 2000 gti :-)

RedGTiVR6 · 11-04-2007, 09:42 PM

considering it hasn't been updated in months?

kilimats · 12-11-2007, 03:39 AM

i am currently doing the same thing on my golf 2002, and i try to see how the screen looked in that position, it was not really comfortable to read because the screen is vertical and the angle isn't appropriate for the eye, it is best to angle the screen a bit to reduce the viewing angle

have you look into that before going kung fu on your bezel ?