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    1. #1
      Join Date
      Jan 2011
      Location
      Boston, MA
      Posts
      1,180
      Country Flag: United States
      I taped off the front in preparation for the fiberglass.



      I started with some fiberglass cloth, resin and hardener.





      Sanded it, added fiberglass mat to the areas I needed to build, sanded it:



      Then started my layers of Bondo Glass:



      I didn't finish the top, since it will not be seen, and I didn't want to build it up due to clearance issues. Since I was going to cover it in vinyl, it just needed to be smooth, but not perfect. If I was going to paint it, I would have moved on to some Bondo body filler for a glass like finish.



      Test Fitting:



      I sprayed the top lip with black plastidip to give it a rubberized finish:



      Started covering it in black vinyl, using 3M 80 Rubber & Vinyl Adhesive:



      I knew I was going to have to have some seams because the angles on the front were pretty complex for someone of, uh, my skill level. I decided to seam it in line with the where the door opens. I probably should have made some grooves with a dremel and flushed it in, but it'll do.









      Test fit:



      Here it is installed:



      Radio is in and working:



      This is a Clarion NZ500 I picked up off eBay. It's a couple model years old, but I actually preferred it because the new models don't have knobs to adjust the volume, just buttons. Touch screen, iPod controls, Nav, backup camera (if I want it):



      A couple more shots of the finished install:








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