It's finally time to wrap up the install on our 2004 Toyota Tundra project.Last month we mounted the amps and did the basic fabrication on the trim panel, so now it's time to finish it up. I get a lot of email about the demo cars we build here at Alpine, and many people ask how we hide the screws and fasteners that hold these cars together. One of the techniques we use is to build inserts over the screws. Not only does this hide the fasteners, but it also allows you to add a different color or texture in your install. The inserts can be painted a contrasting color, wrapped with leather or even built from aluminum or acrylic. Try adding some inserts to your next install instead of showing those screw heads. As always, send your questions to sbrown@alpine-usa.com and check out SteveBrownUniversity.com for more information.
Last month, we left off with our Toyota Tundra amp trim panel partially completed. The fiberglass and Duraglas work is finished, so now it's time to mount it and smooth out the surface.
In order to hide the screws used to mount the panel, we will make inserts over the screw holes. A cardboard template is made first and the final design is sectioned into quarters. This quarter piece is then used to make the final shape to be sure it's symmetrical.
Each plastic piece is cut out with a jigsaw. With pieces this small, it's best to cut slightly outside the line and finish trimming the shape with a grinder.
The cardboard template is placed on the amp panel to check the look and the fit.
An angle die grinder can now be used to trim exactly to the line made by the template.
We did a rough trim on the amp panel in our last installment, but this area near the factory pocket still needs to be trimmed.
The black ABS plastic inserts can now be placed on the panel to position them properly.
An air saw works perfectly to trim fiberglass. It's simply a matter of cutting off the excess along the Sharpie line
The template is then traced onto 1/8" ABS plastic with a sharp pick. Rubbing a little dust into the traced line makes it much easier to see.
Now that it fits the edge of the pocket properly, it's time for final bodywork.
Two layers of masking tape are wrapped around the inserts to gap them for primer and paint. Always use good quality masking tape; Scotch 233+ is excellent
A spreader is used to evenly distribute a thin layer of Rage Gold filler over the entire panel
The next step is to prime the panel in preparation for paint. High-build polyester primers like PCL's Polyprimer work great to fill sanding scratches and pinholes. Twenty cc's of MEKP hardener is mixed with each quart of the primer.
In this install, I decided to match the cosmetics of the Alpine PDX amps with the trim panel. The panel is sprayed with SEM satin black vinyl and plastic paint.
Finally, the amp trim panel can be screwed in place.
The inserts are painted silver to match the screw covers on the amplifiers. I painted these with some silver base coat I had laying around, but something this small could be sprayed with a rattle can silver to get the same effect.
Now is a good time to drill holes under the inserts to mount the panel. Two 3/16" holes are drilled under each insert
Notice how extra filler is added around the insert to make sure it is completely covered
Three heavy coats of polyester primer will fill just about any sanding scratch and pinhole. The paint gun must be cleaned before this stuff starts to harden or it will never spray again!