bd0nalds0n

I've got couple question for guys who fabricated their double din stereo face plates--what did you use to cut the holes that doesn't melt the plastic while doing so? And if you made extras or have a template already made, I'd be happy to buy either.

Jerry Feather

After I formed what I named the "upper insert" for the flush center console conversion to adapt the double DIN units, I then fabricated a router jig or guide that I could place the upper insert in and clamp it around the edges, but out of the way of the router bit. I used some wood and an aluminum plate into which I cut the opening at the correct size to result in the hole I needed. Actually I made two of the router guides so that I could cut the center hole with one and the upper and lower holes with the other one. Then the process of cutting the holes was itself a little complicated since I cut the holes twice.

Do a search for my thread about the Flush Center Console Conversion and I think I have some details in it about this part of the conversion.

Jerry Feather

Brian, there was only one actual question in your initial post, so that is kind of why I only answered one.

However, if I change your last sentence/offer to a question, the answer pretty much depends on precisely what it is you are trying to accomplish. I have blank upper inserts that I don't sell individually. I also have my router guides which I keep to use for the Flush Conversions.

I do, however, have quite a bit of ABS plastic in various thicknesses that I could probably cut a double DIN hole in, but again that kind of depends on what you need and where you need the hole. Also, the hole my guide is designed for is for double DIN after the hole and face of the surround is covered in leather. The leather is about .040 to .050 thick, so the hole in the plastic is that much larger all around.

Then, the question is how thick do you need the plastic to be. Also, where in the plastic should the hole be. Do you need a hole for the upper air vent? How much space should there be between the hole for the air vent and the double DIN? That's assuming that the double DIN will be right below the air vent. Is your final configuration going to be flush or recessed as the original? Where are the HVAC and AC/Lock Panels going to end up? How much space between them and the double DIN?

How are you going to cut the outer edges of the plastic once you have some with a hole or holes in it?
Once you have some plastic with a hole in it, how are you going to mount it in the console?

Jerry Feather

Brian, another approach to what might be your need is rather than cutting a hole into a sheet of ABS plastic, why not just fabricate a surround around what needs to be the hole. By that I mean why not cut some ABS plastic into strips and lay them around something like a wood plug the double DIN size and then glue them together with ABS glue. I would use plastic about half as thick as the final surround needs to be and then using two layers of plastic, overlap my strip joints. ABS glue is only ABS plastic dissolved in MEK, so it makes a solid chemical bond pretty much like welding metal. It wont end up as pretty as clean holes cut in a sheet of plastic, but if you are going to cover it with leather or even vinyl that wont matter. Or, even hand finish it and paint it.

Jerry Feather

Finally, (maybe) it was interesting that you mentioned avoiding a cutting method that would melt the plastic. In fact that is one of the first things that came to mind when I read your post since one of the best methods of cutting plastic is doing just that.

By that I mean you can go to HF or another tool place and buy a soldering gun that comes with a blade-like tip. Use that tip to cut the hole desired cutting (melting) it so that there is enough plastic around the edge to hand file away the melted part leaving the hole cut or filed in clean unmelted plastic..