Sunday:
Today was all about getting the final fit and finish together for the kenwood and AC controls. I would say that this complete DIY requires considerable patience making the modifications to the plastic pieces. The primary tools used for this phase were a razor knife, ruler and dremel.
NOTE: Icemann633 posted great pics of the actual bracket mods neccessary to fit the AC controls into the top slot. Please go to this thread to see Icemann's pics and DIY info:
Custom Lower Console for AC Controls
I removed the lower console again to fix up the AC control and lower pocket alignment, and get rid of that small overhang lip on the bottom pocket.
Further grinding to the top of the pocket edge was required as it was pressing to snuggly against the edge of the AC control, causing it to pop out and over the AC control.
I ground down 1/16" or so in the area of the top pocket lip that touched the AC control (between yellow arrows). kind of 'concaved' it a bit so the AC control would sit down into the pocket lip.
On the underside of the pocket (forgot to get a pic) I also shaved off a bit more than 1/16" from the six support legs (three on each underside) and center "V" shaped tang (flip it over and you will see what I mean)- This allowed the pocket to sit slightly lower in the slot and a bit closer to the top edge of the batwing piece.
Then I needed a way to make sure the pocket was pressed back into the console bracket firmly.
I made an L bracket from an old car stereo back strap that I had in my junk box, and fastened the rear of the pocket to an area of the console body (pressing in the pocket in firmly to seat it beofre screwing it in).
Now, keep in mind I did take the pocket back out after this so I could finish grinding the trim piece for the AC console.
After the trim piece is done and on, then secure the lower pocket in place.
This is how I fastened the AC control to the console bracket. No front screws needed, there is a lot of empty plastic on that AC control body so it is fine to shoot a couple of screws into it from either side (rear arrow), towards the upper half of the AC control (by hand, use self-taps, don't use a screw gun).
once you put both screws in, do not tighten yet- just make it snug but still moveable.
The front arrow, I used two 'speed clips' from an old speaker installation kit (again from the ever-handy drawer-o-junk) and slid them on over the plastic ears of the AC control to space it forward about 1/16".
This will help with the alignment.
Ok- moving on to the actual trim for the AC control.
I dissected the oem trim piece and you will start with cutting off the bottom right at the lower part of the curved inside opening.
easiest way is to use a dremel with a thin cutoff wheel. note that the outer edge of the cut should slope down so it hugs the curve of the lower pocket top edge.
As this pic shows, you will want to cut off about half of the thickness on the top of the trim piece. It gets in the way and keeps things from lining up. Use a steady hand and a dremel cutoff wheel.
Now things get fun.. There is a dropped lip on the very top plastic piece of the console. when you put the AC control in place it pushes down on things and screws up the alignment. I decided to make a channel on the trim piece for this upper lip to fit into and relieve the downward pressure.
Use a dremel cutoff wheel to score the channel, then use a grinding barrell to reduce the height of the plastic on the back side of the channel. You want to end up with a little less than 1/8" sticking up along the front part of the trim and about a bit less than 1/8 thick.
When you are done with this part, and you have the AC control in place in the top slot, place the trim around the AC control and put the lower pocket in to check for fit.
You are going to have to do this several times until you have ground off enough of the plastic on the top lip of the lower pocket and the AC trim piece to get everything to fit snugly. After you get everything to fit and lined up, tighten up the two side screws that will secure the AC control and screw the lower pocket to the L bracket.
Here is the console assembled and properly aligned:
Now that that is done and back in the car, I needed to make a decent looking trim piece for the kenwood unit that would cover the top/bottom gaps and make it look as integrated as possible. I bought a nice big piece of Metra ABS (order from an online car stereo store) for this- but lo and behold.. Kenwood gives you a super-sweet huge 'universal' trim piece for use in several different cars.
So the center cut was already finished, making my job easier. I just needed to measure and trim the outside (they give you about 2" all around).
Now, since I had that nice piece of Metra:
I decided that I should use the Metra to cut out a 'cover piece' for times when I don't want that beautiful 7" screen visible to the public. PLUS, my gf's X3
just got broken into last night right here outside my house and they stole her TomTom GPS.. They completely smashed in the driver's window. @$$holes!
Here's the finished cut-out for the kenwood trim and the 'stealth' blank plate:
(continued - 10 picture link limit per post?????)