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Sony Honda Civic Si Chamfered Lcd Pod
The 11/42" MDF was chamfered... 
   
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Sony Honda Civic Si Chamfered Lcd Pod
The 11/42" MDF was chamfered to allow for the six layers of fiberglass that would be built up on the edge.
Sony Honda Civic Si Framework
To create the framework for... 
   
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Sony Honda Civic Si Framework
To create the framework for the gauge pod, 11/44" MDF templates were cut.
Sony Honda Civic Si Routed Framework
The strips were routed on... 
   
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Sony Honda Civic Si Routed Framework
The strips were routed on the inside to allow for gauge clearance and wiring.
Sony Honda Civic Si Steel Brace Glued In Place
The complete gauge pod with... 
   
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Sony Honda Civic Si Steel Brace Glued In Place
The complete gauge pod with 11/44" steel bracing and all of the MDF framework was glued into place and ready for molding.
Sony Honda Civic Si Green Foam
Green foam was cut and glued... 
   
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Sony Honda Civic Si Green Foam
Green foam was cut and glued into place and carved into shape between the MDF ribs.
Sony Honda Civic Si Glued Foam
Here's a picture of the entire... 
   
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Sony Honda Civic Si Glued Foam
Here's a picture of the entire console/gauge pod with the foam glued in place.
Sony Honda Civic Si Fiberglass
A layer of fiberglass mat... 
   
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Sony Honda Civic Si Fiberglass
A layer of fiberglass mat and resin was applied to the entire mold.
Sony Honda Civic Si Cured Fiberglass
The fiberglass was allowed... 
   
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Sony Honda Civic Si Cured Fiberglass
The fiberglass was allowed to cure for seven days and the high spots were ground down in preparation for body filler.
Sony Honda Civic Si Body Filler
Several even coats of Rage... 
   
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Sony Honda Civic Si Body Filler
Several even coats of Rage Gold body filler were applied to the entire mold.
Sony Honda Civic Si Sanded Body Filler
The body filler, shown here,... 
   
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Sony Honda Civic Si Sanded Body Filler
The body filler, shown here, was sanded until smooth.
Sony Honda Civic Si Final Test Fit
The complete, sanded mold... 
   
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Sony Honda Civic Si Final Test Fit
The complete, sanded mold was placed in the car for a mock-up with all of the gauges, displays and wires test-fit in their proper position.
Sony Honda Civic Si Custom Stand For Paint
A stand was built out of steel... 
   
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Sony Honda Civic Si Custom Stand For Paint
A stand was built out of steel and wood to hold the gauge pod securely so that it could be painted on all sides uniformly.
Sony Honda Civic Si Primer
Three coats of high-built... 
   
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Sony Honda Civic Si Primer
Three coats of high-built 2K primer were sprayed on the mold, while a space heater assisted in the curing process.
Sony Honda Civic Si Wet Sand Primer
The primer was wet-sanded... 
   
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Sony Honda Civic Si Wet Sand Primer
The primer was wet-sanded and prepped for paint.
Sony Honda Civic Si Basecoat
The mold was sprayed with... 
   
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Sony Honda Civic Si Basecoat
The mold was sprayed with 10 coats of Xotic basecoat to create the custom silver flake.
Sony Honda Civic Si Ocean Paradise Blue Green
Ocean Paradise blue-green... 
   
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Sony Honda Civic Si Ocean Paradise Blue Green
Ocean Paradise blue-green candy paint was applied over the custom silver flake and clearcoated with the final finish.
Sony Honda Civic Si Finished Product
The finished gauge pod.

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