Small project I would appreciate some help with!

[GE90]

Hi All

I really don’t know whether anyone is able to offer any assistance, but I’ve been trying to complete a little project involving my car, and to date have failed miserably!

In summary I need someone with possibly plastic laser cutting equipment and knowledge to make the internal cutout size of an interior radio surround larger, to accommodate a larger screen!

The reason for all my effort is that VW do not sell one in the trim finish I need - I am retrofitting.

I don’t know whether this is even possible, but there must be a technique I could adopt or a professional fabricator who might be able to assist? Or am I wasting my time even trying??!!

FROM THIS



TO THIS



Thank you.

[anonymous-user]

Dremel and steady hands.

[paradigital]

I’m certainly no expert when it comes to working plastics, but I’d have thought it infinitely easier to paint the “correct” one than to cut a painted one down to size without needing remedial paintwork anyway.

EDIT: What’s the part number for both parts?

[GE90]

Thanks very much.

Unfortunately the finish is a bespoke GTI interior almost carbon effect, so impossible to match.

Steady hand is the issue!!

[Getragdogleg]

Hydro dip the correct pattern onto the correct part.

[GE90]

Love the this suggestion, but it is a repeating regular pattern....

Thanks

[Penelope Stopit]

Cut most of the material off with a machine or a knifes hot blade, file off the remainder, achieved several times in the past

Support on block of wood during filing so that the fascia doesn't crack

Mmmmm, perhaps you won't be happy with the straight edge finish

Edited by Penelope Stopit on Sunday 17th November 09:19

[GreenDog]

Find someone with a steady hand who can cut it for you, a local model maker perhaps ?

[Jamescrs]

Looking at the first picture I wonder if wrapping the new part in a gloss black vinyl would work?

[Getragdogleg]

Some of the hydro dip companies do an incredible range, pretty sure they can design and print what ever you want

[GreenV8S]

GE90 said:

Unfortunately the finish is a bespoke GTI interior almost carbon effect, so impossible to match.

I can't make out the surface finish very well, but there are people selling carbon fiber patterned wrap designed to be applied to wing mirrors and the like. It will probably be easier to add the finish to the right part, rather than try to match a glossy moulded finish on something hand made.

[Getragdogleg]

Seriously, hydro dipping. They can do anything.

I'm sure your pattern is possible.

[GE90]

Here is the pattern:

[Getragdogleg]

Take the part with the pattern on to a good hydro dipper.

Maybe they can scan it and print it, then put it on the correct part and seal it with clear lacquer.

Hopefully, job done.

[tapkaJohnD]

Find somewhere that will scan your target part into a CAD programme. OR, the original part and then modify it in CAD to the dimensions you want.

Use the CAD to make a mould, a negative image of the target part by 3D printing.

Contruct the new part in GRP by laying it up in the mould, using the right (if you can find it) pattern of carbon fibre in the gelcoat. I don't think that any economic additive manufacturing material would tolerate the autoclave to make it in actual carbon fibre.

John

[GreenV8S]

tapkaJohnD said:

Use the CAD to make a mould, a negative image of the target part by 3D printing.

Turning a 3d model into a mould that you can use to lay up a perfect gloss finish on a fine detail part is a massive undertaking. Hand-trimming the original part would probably work out easier, although still a very demanding job.