Thanks for all of the compliments, guys.
Originally Posted by jachin
How did u make the edges roll in around the HU. was it all hand sanded that way or was it routed or what
The curved edges on the left, right and bottom of the radio opening were all hand shaped. The top was largely untouched. A plug was used to keep the opening accurate, It'* made from 1 x 12 material (3/4" thick) and 1/2" plywood. Essentially, the edges were square when it was released from the plug. I used a Dremmel with the larger sanding wheel with 80 grit to rough shape. Then 120 sandpaper, 220 and finally 320. The corners were a little difficult but I found by wrapping sandpaper around drill bits of varying diameters, I was able to make nice transitions. The HUD switch opening was shaped from the reverse mold of the original. I was pretty impressed with how that came out. My first time with reverse molds.
I'd like to do some custom work but I don't even have a garage to work in. Next year we plan on a 26 x 30 garage plus a kitchen addition but this was planned for 2004. Needless to say, it didn't happen.