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Sony Honda Civic Si Cured Fiberglass Mold
The headliner mold shown here... 
   
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Sony Honda Civic Si Cured Fiberglass Mold
The headliner mold shown here in its final shape was allowed to cure for seven days.
Sony Honda Civic Si Fiberglass Cut To Shape
The fiberglass mold was cut... 
   
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Sony Honda Civic Si Fiberglass Cut To Shape
The fiberglass mold was cut to the Sharpie lines with an airsaw at slow speed. A chipboard template was made prior to drilling the mounting holes.
Sony Honda Civic Si Fiberglass Cut To Shape
A 0.25" piece of black ABS... 
   
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Sony Honda Civic Si Fiberglass Cut To Shape
A 0.25" piece of black ABS plastic was cut to serve as a base for the gauge structure. The smooth, black plastic will be easier to finish in the painting/priming process.
Sony Honda Civic Si Ground Down Abs
The plastic was ground down... 
   
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Sony Honda Civic Si Ground Down Abs
The plastic was ground down with an air grinder to promote adhesion and scored for the addition of an MDF brace.
Sony Honda Civic Si Headliner Installed With Fiberglass Mold
The headliner was re-installed... 
   
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Sony Honda Civic Si Headliner Installed With Fiberglass Mold
The headliner was re-installed and the fiberglass mold was bolted into place.
Sony Honda Civic Si Abs Base
The ABS/MDF centerpiece was... 
   
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Sony Honda Civic Si Abs Base
The ABS/MDF centerpiece was glued into place.
Sony Honda Civic Si Checking For Alignment
The ABS strip visible from... 
   
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Sony Honda Civic Si Checking For Alignment
The ABS strip visible from the center windshield was checked for proper alignment.
Sony Honda Civic Si Mold Mounting Screws
The headliner mold bolts to... 
   
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Sony Honda Civic Si Mold Mounting Screws
The headliner mold bolts to the factory sunvisor mounting spots with M6 bolts.
Sony Honda Civic Si Gauges Glued To The Center Structure
To house the four Faze gauges,... 
   
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Sony Honda Civic Si Gauges Glued To The Center Structure
To house the four Faze gauges, 11/42" MDF rings were cut, flush-routed and CA glued to the center structure.
Sony Honda Civic Si Gauge Pod Structure
A template was made for the... 
   
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Sony Honda Civic Si Gauge Pod Structure
A template was made for the gauge pod using plumber's tape, later transferred to a 0.25" steel brace. This will keep the mold from changing shape due to temperature and humidity changes in the car.
Sony Honda Civic Si  Tracing The Lcd
Here is the Beltronics LCD... 
   
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Sony Honda Civic Si  Tracing The Lcd
Here is the Beltronics LCD display traced onto 11/42" MDF to create a template. This will be mounted at the junction of the overhead and the gauge pod.
Sony Honda Civic Si Test Fitting The Template
The template was test-fit... 
   
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Sony Honda Civic Si Test Fitting The Template
The template was test-fit before gluing into place.
Sony Honda Civic Si Lcd Housing
The template was transferred... 
   
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Sony Honda Civic Si Lcd Housing
The template was transferred to 11/42" MDF and cut out. This was glued to 11/44" MDF strips to make a housing for the LCD display.
Sony Honda Civic Si Lcd Housing Glued In Place
The MDF was routed at a 45-degree... 
   
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Sony Honda Civic Si Lcd Housing Glued In Place
The MDF was routed at a 45-degree angle and glued into place.
Sony Honda Civic Si Test Fitting With Wiring
The LCD display and wiring... 
   
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Sony Honda Civic Si Test Fitting With Wiring
The LCD display and wiring was test-fit in the housing before being glued to the structure.

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