| AWDCRAZY | 11-11-2004 11:19 PM |
DIY, Custom A Pillar Instructions
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[COLOR=Red]Material List:[/COLOR]
Home Depot/Hardware store
Fiberglass Resin
Fiberglass Cloth/Mat
Box of 50 Rubber Gloves
Extra Fiberglass Resin Hardener
1 gallon Tub of Bondo.
Bondo mixing and applying plastic spreaders
Light weight finishing filler, (5 oz tube)
40 grit sand paper
120 grit sand paper
320 grit sand paper
primer
paint
Small amt of 1/2 inch MDF Wood 4ft sq should be enough
Large Roll of Aluminum Foil
Package of Mixing Cups or SOLO cups,
[COLOR=Red]Tools needed[/COLOR]
POWER SANDER IS A BIG HELP
Scisors or razor blades
Jig Saw
Imagination
[COLOR=Red]FIRST STEP: Making the Mold to build from.[/COLOR]
Remove A Pillar Trim Covers.
Cover A Pillar Trim Piece in Aluminum foil, 2 layers should be good,
press the foil so there is no creases and it wraps the trim piece tight
Lay out dry fiberglass mat on Pillar, cut to fit shape,
2 layers should be fine to start...
(you are covering the outside shell, not wrapping it around
the back.)
Put on Gloves, Mix 5-10 Oz of Fiber glass resin in Cup
according to the packages requirements,,,MIX WELL.
Use your hands and work resin into the Mat, Continue to
make sure that the mat holds the shape that you are recreating.
DO this on both pillars and wait till they dry, 2-6 hours depending
on temperature.
Once dry, remove hard shell from original pillar trim piece and pick
the aluminum off of the mold you have made.
[COLOR=Red]STEP TWO. Creating the shape.[/COLOR]
This part takes some creativity on your part, Now that you have
seen how Fiber glass works, You need to learn and play with how
you want your pillar to look, are you adding speakers, Gages, Mounts
Displays, SAFCII Screen, MBC's etc.
Use the Wood to cut guides for your self. Our example will be tweeter POD.
Cut the wood to reflect a ring the size of which the tweeter
will fit in snug.
Use Small amt of bondo, (mix according to instructions on can)
to secure the wood to your New Mold. Mix the bondo HOT, or
add a little more cream hardener than your would for normal.
(this is just expierence, play with the stuff a little bit
before you start your project) You can see in this picture the
small plastic mounting ring that was used, see how it is atached
with the bondo to the mold!!
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_6_full.jpg[/IMG]
Let dry, the HOT mix bondo will harden in about 3-5 min.
You will have to hold the wood in that spot until it drys.
Now Mix normal proportions of cream hardener and bondo and fill in
area behind the wood trim piece, use Gloves and use a bondo spreader.
(this will cause less sanding later)
Let this harden and continue to sand down and apply bondo until you have
the shape that is desired.
as you can see here, the plastic trim ring is now back filled and the middle
cleared out.
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_7_full.jpg[/IMG]
Use Dremel tool or drill to remove excess bondo from inside the wood trim
ring, you can also put the tweeter into a plastic bag before bondo and put it
in the trim ring you made,then bondo around it, same idea as the aluminum
over the pillar trim ring, it does not stick but allowes it to be molded
around the part.
[COLOR=Red]Part 3: Finishing the pillar.[/COLOR]
At this point you should have a basic looking pillar with lots of
funny colors on it.
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_9_full.jpg[/IMG]
Use your light weight bondo filler tube to fill in small irregularities on
the surface of your new Trim Pieces, Use the 320 grit to make is as smooth
and flowing as possible, you might want to lay another layer of fiberglass
mat over the project at this point to have a uniform surface and to add strength.
Bondo sands easier than resin and having the surface uniform with one product
will make it easier to sand and make just perfect.
next is to spray with primer and let dry, this will show
off the wavy or uneven parts. let dry and
finish sanding it down and filling imperfections and re spray with primer
until you have it as smooth as you want it to be.
Next hit the piece with SEM Texture coat spray, follow the instructions
on the can very carefully, dont rush this part. This will give the
New Trim Piece a texture that looks like leather or the factory plastic
dash texture. Follow the finishing instructions on the can
exactly so it turns out just right, remember at this point,
you can always sand it down and try again until it is just right
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_11_full.jpg[/IMG]
Last part is to paint it what ever color you want!
and you are done
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_31_full.jpg[/IMG]
Home Depot/Hardware store
Fiberglass Resin
Fiberglass Cloth/Mat
Box of 50 Rubber Gloves
Extra Fiberglass Resin Hardener
1 gallon Tub of Bondo.
Bondo mixing and applying plastic spreaders
Light weight finishing filler, (5 oz tube)
40 grit sand paper
120 grit sand paper
320 grit sand paper
primer
paint
Small amt of 1/2 inch MDF Wood 4ft sq should be enough
Large Roll of Aluminum Foil
Package of Mixing Cups or SOLO cups,
[COLOR=Red]Tools needed[/COLOR]
POWER SANDER IS A BIG HELP
Scisors or razor blades
Jig Saw
Imagination
[COLOR=Red]FIRST STEP: Making the Mold to build from.[/COLOR]
Remove A Pillar Trim Covers.
Cover A Pillar Trim Piece in Aluminum foil, 2 layers should be good,
press the foil so there is no creases and it wraps the trim piece tight
Lay out dry fiberglass mat on Pillar, cut to fit shape,
2 layers should be fine to start...
(you are covering the outside shell, not wrapping it around
the back.)
Put on Gloves, Mix 5-10 Oz of Fiber glass resin in Cup
according to the packages requirements,,,MIX WELL.
Use your hands and work resin into the Mat, Continue to
make sure that the mat holds the shape that you are recreating.
DO this on both pillars and wait till they dry, 2-6 hours depending
on temperature.
Once dry, remove hard shell from original pillar trim piece and pick
the aluminum off of the mold you have made.
[COLOR=Red]STEP TWO. Creating the shape.[/COLOR]
This part takes some creativity on your part, Now that you have
seen how Fiber glass works, You need to learn and play with how
you want your pillar to look, are you adding speakers, Gages, Mounts
Displays, SAFCII Screen, MBC's etc.
Use the Wood to cut guides for your self. Our example will be tweeter POD.
Cut the wood to reflect a ring the size of which the tweeter
will fit in snug.
Use Small amt of bondo, (mix according to instructions on can)
to secure the wood to your New Mold. Mix the bondo HOT, or
add a little more cream hardener than your would for normal.
(this is just expierence, play with the stuff a little bit
before you start your project) You can see in this picture the
small plastic mounting ring that was used, see how it is atached
with the bondo to the mold!!
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_6_full.jpg[/IMG]
Let dry, the HOT mix bondo will harden in about 3-5 min.
You will have to hold the wood in that spot until it drys.
Now Mix normal proportions of cream hardener and bondo and fill in
area behind the wood trim piece, use Gloves and use a bondo spreader.
(this will cause less sanding later)
Let this harden and continue to sand down and apply bondo until you have
the shape that is desired.
as you can see here, the plastic trim ring is now back filled and the middle
cleared out.
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_7_full.jpg[/IMG]
Use Dremel tool or drill to remove excess bondo from inside the wood trim
ring, you can also put the tweeter into a plastic bag before bondo and put it
in the trim ring you made,then bondo around it, same idea as the aluminum
over the pillar trim ring, it does not stick but allowes it to be molded
around the part.
[COLOR=Red]Part 3: Finishing the pillar.[/COLOR]
At this point you should have a basic looking pillar with lots of
funny colors on it.
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_9_full.jpg[/IMG]
Use your light weight bondo filler tube to fill in small irregularities on
the surface of your new Trim Pieces, Use the 320 grit to make is as smooth
and flowing as possible, you might want to lay another layer of fiberglass
mat over the project at this point to have a uniform surface and to add strength.
Bondo sands easier than resin and having the surface uniform with one product
will make it easier to sand and make just perfect.
next is to spray with primer and let dry, this will show
off the wavy or uneven parts. let dry and
finish sanding it down and filling imperfections and re spray with primer
until you have it as smooth as you want it to be.
Next hit the piece with SEM Texture coat spray, follow the instructions
on the can very carefully, dont rush this part. This will give the
New Trim Piece a texture that looks like leather or the factory plastic
dash texture. Follow the finishing instructions on the can
exactly so it turns out just right, remember at this point,
you can always sand it down and try again until it is just right
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_11_full.jpg[/IMG]
Last part is to paint it what ever color you want!
and you are done
[IMG]http://memimage.cardomain.net/member_images/5/web/389000-389999/389369_31_full.jpg[/IMG]
| Hank3 | 11-11-2004 11:31 PM |
Wow - way to be creative and resourceful. Two thumbs up :)
| BlackAndBlue | 11-11-2004 11:38 PM |
nice, what SEM texture paint and what color is that, matches really well
| kennyvb | 11-12-2004 12:04 AM |
nice fab
| garie | 11-12-2004 12:21 AM |
very very nice work.
| AlucardR | 11-12-2004 12:47 AM |
Submit this to Scoobymods.com if you haven't already
| wrxinmn | 11-12-2004 01:13 AM |
sweet dude, i already have 8 speakers but youve given me a good idea for numbers 9 and 10! i've already got my comp tweeters pretty close to that location. how would some 3.5" coax do towards the top, angled down? is 3.5" even a worthwhile size?
i'd think a big ol 6.5" might either look ridiculously out of place or be an obstruction?
i'd think a big ol 6.5" might either look ridiculously out of place or be an obstruction?
| imprezaboi | 11-12-2004 01:37 AM |
Very cool mod!
| imprezivenycz | 11-12-2004 08:59 AM |
proper mod! now just factor inside some 60mm A Pillar gauge housings for the driver side...hehe
| 128d | 11-12-2004 11:42 PM |
Looks very nice, its almost looks OEM. Great job.
| wrxinmn | 11-13-2004 10:40 AM |
i suppose this could partially be done to the rear pillars as well? theyre a lot wider and would be accomodating to a 6.5" in the upper corners. it would have to sorta fit like a lip since the seatbelt connections there but it might be cool just the same.. but then again i also have speakers in the back doors, back deck, and back armrest. yea i think the rear is covered...
| Tobey | 11-13-2004 05:06 PM |
not too shabby, and this could be used for just about anything. nice writeup!
| DaveDangerous | 10-05-2005 01:30 PM |
Great write up!! Impressive :D
| deluxsti | 10-05-2005 02:37 PM |
too bad you did that ot an evo JK, nice
| IIdiceII | 10-05-2005 09:59 PM |
Great custom work. 2 thumbs way up!!
| vorlon333 | 10-05-2005 10:02 PM |
looks great, I may have to try this
| vwown3d | 10-05-2005 10:59 PM |
dam, nice work
| jason2004STI | 10-05-2005 11:01 PM |
Very nicely done, Congratz on something original!
Peace
Jason
Peace
Jason
| BOOST3DWRX | 10-05-2005 11:12 PM |
wow impressive nice job!
| marshallw | 10-06-2005 10:57 AM |
Very nice. The A Pillar project has been calling my name and now with this great write up, I may just have to tackle it. Well done.
| sneeky | 10-06-2005 11:02 AM |
That does look great. do you have a close up of how the texture paint layer turned out? thinkin about using it, but I want to make sure I like the look before doing it.
chris
chris
| Blackboxracing | 10-06-2005 11:52 AM |
som1 please sticky this!
| Phy6 | 10-06-2005 11:57 AM |
Hmm...last post didn't work. Nice! and subscribe. I have a 6.5" component set that begs to be high like this...time to get creative!
| WRX-ERROR | 10-06-2005 11:58 AM |
Hehe ok for a second there I thought you were putting gauges in there. I thought to myself WT F is he going to fit into that large hole and how is he going to see any gauge in that small one.
Anywho, nice writeup. Back when I was younger and into car audio this would be on my list of mods for sure.
Anywho, nice writeup. Back when I was younger and into car audio this would be on my list of mods for sure.
| nuclear | 11-20-2005 12:41 PM |
For the initial first layer did you use cloth or mat? Thickness?
I'm having a difficult time getting it to retain the shape on the sides of the pillar and I'm not exactly going to stand there holding it againt the pillar for 6 hours :huh:
My thought at the moment is that I used a thick mat that wasn't as workable as I would have liked it to be..
I'm having a difficult time getting it to retain the shape on the sides of the pillar and I'm not exactly going to stand there holding it againt the pillar for 6 hours :huh:
My thought at the moment is that I used a thick mat that wasn't as workable as I would have liked it to be..
| redsube' | 11-28-2005 11:31 AM |
awesome descriptive write- up
way to be original!!!!
way to be original!!!!
| Phy6 | 11-28-2005 12:13 PM |
So what size speakers are those? 5.25" or 4" ?
| Damon | 11-28-2005 01:34 PM |
looks awesome. :)
| 2fas4u | 11-28-2005 06:51 PM |
Sweet job!!
| NewDriverOlderRide | 11-28-2005 07:10 PM |
Beautiful!
| rukkie | 11-28-2005 11:38 PM |
I was thinking to myself, "oh man what now..."
but damn I was wrong! Nicely done bro!
but damn I was wrong! Nicely done bro!
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