Quote:
Originally Posted by GregWeld
Great post John!
Now you've got to finish it! |
Got it covered already! When I started the project I wasn't sure it could be done they way I wanted and had never worked with carbon fiber before, so few people knew I was attempting it. I took notes and pics instead of posting then in case the project turned into a failure. I wrote the whole thread in my "spare" time the past week and there's about 80 pics incorporated so I'm going to post it up a bit at a time.
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Very carefully cut the shape of the facia out of the posterboard along the inner edge of the circumference line you made. Do Not cut out any of the openings for gauges etc. Sand the posterboard until you have an exact fit within the bezel. If you are off more than 1/16" you will have gaps where the posterboard does not fit perfectly into the bezel.
Now lay the posterboard cut out onto a thin sheet of ABS you'll be using for mock up. (If you're really confident in your skills and plan you could skip to the carbon fiber or final material you are going to use but I recommend fitting everything with cheap plastic first.)
Tape the posterboard in place so it cannot move and trace the outline onto the plastic with a grease pencil. Then remove the posterboard and cut out the facia shape using a Dremel with a cutting bit. Do not try to cut it exactly to the correct size. After you've cut the shape out, sand down to its final size using 80 grit paper to fit perfectly into the bezel. The plastic shown in the pics is fake carbon fiber. It's very realistic looking but does not reflect light with the same prism effect of the real stuff.
