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Discussion Starter · #1 ·
After long time,I understand that I won't be able to find a suitable pod,and the Apillar is not so good because of airbag.<p>Yesterday I started to make my own pod.After finishing I will cover it with leather.<p>The pod will be located to the center speaker's place.I used the bottom plastic part and didn't touch the original grille.(The grille maybe necassary in the future when the car will be sold).<p>I used smaller diameter center speaker grille(13 cm),it is enough for those frequencies.However the center speaker is for high frequencies,what is the reason for a 16 cm one?!<p><br><A HREF="http://imageshack.us" TARGET="_blank"><IMG SRC="http://img453.imageshack.us/img453/2618/080520066mf.jpg" BORDER="0"></A><p><A HREF="http://imageshack.us" TARGET="_blank"><IMG SRC="http://img453.imageshack.us/img453/402/080520060018hw.jpg" BORDER="0"></A><p><A HREF="http://imageshack.us" TARGET="_blank"><IMG SRC="http://img335.imageshack.us/img335/6059/080520060028cf.jpg" BORDER="0"></A><p><A HREF="http://imageshack.us" TARGET="_blank"><IMG SRC="http://img335.imageshack.us/img335/7868/080520060034mh.jpg" BORDER="0"></A>
 

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Re: (xenophobic)

That is going to look very sharp.<br>What are you using for the "frame". The brown stuff. It looks like you shaped the pod easily from it.
 

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Discussion Starter · #4 ·
Re: (Our R)

aaaa,I don't know the english name.It is a board,the material used for the subwoofer cabins.
 

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MDF
 

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Re: (phuz)

yes MDF but I thought it was different in English....sorry <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/confused.gif" BORDER="0">
 

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what is MDF? <p>is it the flat board thing or can you use this stuff to make those pods? how? <p>could I get this stuff and fab my own gauge pod up by the sunroof controls? like Kai's setup?
 

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Re: (23109VC)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>23109VC</b> »</i></TD></TR><TR><TD CLASS="quote">what is MDF? <p>is it the flat board thing or can you use this stuff to make those pods? how? <p>could I get this stuff and fab my own gauge pod up by the sunroof controls? like Kai's setup?</TD></TR></TABLE><p>MDF is Medium Density Fibreboard, typically made form saw dust and used for baseboards, mouldings, casings, etc. Very easy to work with! Available in any home center, Lowes, Home Depot, etc.<p>Later,<p>
 

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Re: (23109VC)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>23109VC</b> »</i></TD></TR><TR><TD CLASS="quote">what is MDF? <p>is it the flat board thing or can you use this stuff to make those pods? how? <p>could I get this stuff and fab my own gauge pod up by the sunroof controls? like Kai's setup?</TD></TR></TABLE><p>See above post for MDF.<p>Working the MDF should be easy, you can get stock anywhere. Usually in most auto applications (for subwoofer enclosures, door pods, etc.) the MDF is then covered in a layer of fiberglass or bondo. You can get it at any auto parts store. That way you'll have a nice smooth surface that you can shape with a sander / sandpaper and will take paint well.
 

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Re: (needsdecaf)

so does MDF come in flat sheets, like thin plywood? or in big chunks/blocks that can be gut/ground down to the desired shape?<p>for example - to make that pod - it's a large round ball shape - was that made by cutting/grinding a square/rectangular block of the stuff...or is this stuff soft/malleable and you "sculpt" it??
 

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Re: (23109VC)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>23109VC</b> »</i></TD></TR><TR><TD CLASS="quote">so does MDF come in flat sheets, like thin plywood? or in big chunks/blocks that can be gut/ground down to the desired shape?<p>for example - to make that pod - it's a large round ball shape - was that made by cutting/grinding a square/rectangular block of the stuff...or is this stuff soft/malleable and you "sculpt" it??</TD></TR></TABLE><p>MDF Comes in many shapes / sizes / thicknesses. It comes in sheet stock and blocks as well.<p>In the case of his gauge pods, if you look closely at his picture, it looks like he fabbed the pods by making several concentric hollow rings out of the mdf, gluing them together and sanding it smooth. <p>Think of it like wood. It can be worked just like wood, only a bit easier. To make a pod like that, I'd get some 1/2 thick sheets, cut them into concentric rings on the jigsaw or with a router, glue them together, then sand them smooth. <p>You can also screw it as well. The best way to think of making complex shapes is to form the basic shape a bit smaller and square, then level it and shape it with fiberglass or bondo. <p>
 

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Discussion Starter · #14 ·
Re: (23109VC)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>23109VC</b> »</i></TD></TR><TR><TD CLASS="quote">so does MDF come in flat sheets, like thin plywood? or in big chunks/blocks that can be gut/ground down to the desired shape?<p>for example - to make that pod - it's a large round ball shape - was that made by cutting/grinding a square/rectangular block of the stuff...or is this stuff soft/malleable and you "sculpt" it??</TD></TR></TABLE><p>To shape the mdf:I first started with a rectangular shape,then I used some thick sandpapers,some black&decker eletrical sanding machine tools,electrical saw and etc.<p>If you only have sandpaper,yes it is possible to shape but takes some time more.
 

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Re: CUSTOM MADE GAUGE POD!PROJECT STARTED (xenophobic)

Great job xenophobic! I have been contemplating making a single pod for my steering column out of ABS plastic and having it covered in cabon fiber. You solution sounds even more elegant than mine. I will be very curious to see how it turns out. Nice planning with the center speaker cover and all <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> .
 

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cool. too bad I haven't got any of those tools... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/frown.gif" BORDER="0"><p>i'll just have to pay to have a stereo shop make me one...
 

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Re: (23109VC)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>23109VC</b> »</i></TD></TR><TR><TD CLASS="quote">cool. too bad I haven't got any of those tools... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/frown.gif" BORDER="0"><p>i'll just have to pay to have a stereo shop make me one...</TD></TR></TABLE><p>Shouldn't be expensive. MDF is cheap, and you're not talking anything large / complicated. The most complicated and important thing is that you understand how you are going to connect it to the console and plan accordingly. Screws, clips, blind nuts, etc. can all be integrated into the MDF if you plan ahead. Of course, I have never taken the overhead console apart...you may just be able to screw right through it into the gauge holder.
 

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Discussion Starter · #18 ·
Re: (needsdecaf)

I used some adhesive paste to cover the edges,to make the edges good lined.<p>I used the original plastic bottom and used hot 404 glue to stick the MDF on it.<p>After sticking the MDF I used the paste to fill the empty places.<p>TEST:After drying ,I accidently dropped the part,it was still good!<p>But my mobiles charge was off so I couldn't take more pictures.Tomorrow will post new ones.
 

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I've already taken out the cover that fits into the sunroof area. it just sets in there - no clips or anything. it has some grooves that allow ti to rest in place.<p>i think the easiest way to add gagues to it woudl be to cut out the center of it - then graft the pods into it and hope that one could cover the whole thing in epoxy/bondo/etc and sand it all smooth then paint it. the end resutl would go right back into place.<p>it's fairly easy to undo the top console thing and pop out that little cover thing. i did it on mine. i just need to figure out how to make my own gauge clusters and get them to bond to the cover. i'll look into this stuff.
 

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Re: CUSTOM MADE GAUGE POD!PROJECT STARTED (xenophobic)

xenophobic,<p>What gauge are you going with for your pod? Very nice workmanship on the two pods - did you find a leather to match the dash or the black leather on the cluster cover?<p>- Tryg
 
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