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Blog Post

Custom overhead console

03 Aug 2018
0 Comment
Vedran Relja
Ford Capri Build Log

Knight rider’s, Blade Runner’s, Mad Max’s car and almost every space ship has an overhead control panel, so naturally, Capri needed to have one, too. Creating and mounting it became a bigger challenge than anticipated.

Custom Capri overhead console

After the initial design, we could start working on the piece. An illustration above is actually a 3D sketch done by my friend, who made it out of my 2D designs just to show how complicated was the build of the relatively simple looking finished unit.

After the initial measurement and brainstorming, I started with drilling holes for the rivet nuts, and main anchor points for the console.

Custom Capri overhead console

Inserting the steel rivet nut.

Custom Capri overhead console

With the use of flexible glue, original rear view mirror mount was covered, so the headliner doesn’t distort on that particular part of the roof.

Custom Capri overhead console

Everything was leveled with a piece of Forex.

Custom Capri overhead console

After the CAD designs, some parts were laser cut and the assembly of the console has started.

Custom Capri overhead console

First piece done.

Custom Capri overhead console

Prepping for the zinc plating.

Custom Capri overhead console

Some pieces were powder-coated and some were zinc plated.

Custom Capri overhead console

CNC cutting of  the Forex sheets.

Custom Capri overhead console

Punching out the holes.

Custom Capri overhead console

It fits!

Custom Capri overhead console

Time for the upholstery.

Custom Capri overhead console

I found out that the double sided tape works great for the temporary adhesion before sticking.

Custom Capri overhead console

Also i used the automotive upholstery glue.

Custom Capri overhead console

Couple of hours of drying.

Custom Capri overhead console

Thickness of the complete panel is stretching the limits of my sewing machine.

Custom Capri overhead console

This plastic tool was really helpful in pushing in the stubborn fabric.

Custom Capri overhead console

The model of the mounting bracket is fabricated.

Custom Capri overhead console

Nice view from the top to the bottom; my model, crappy bending from the local shop and precision bending from a high quality shop.

Custom Capri overhead console

Line for the angle.

Custom Capri overhead console

That was simple enough.

Custom Capri overhead console

Some more rivet nuts, embossing the holes and test fit.

Custom Capri overhead console

Using the hydraulic punching tool for some lightening holes.

Custom Capri overhead console

Test fit.

Custom Capri overhead console

Test fit of the roof bracket – for this mock-up I was using long bolts, so that’s why you see all those washers.

Custom Capri overhead console

It’s going to be a tight fit for connectors.

Custom Capri overhead console

First try.

Custom Capri overhead console

Everything looks aligned and ready for the next step.

Custom Capri overhead console

Patching up a couple of holes.

Custom Capri overhead console

A thick piece of Forex has been CNC milled to make a cover for the switches.

Custom Capri overhead console

Some gluing and cutting later.

Custom Capri overhead console

Sinking into the holes.

Custom Capri overhead console

In order to make the alcantara material more flexible, I removed its cotton backing.

Custom Capri overhead console

Some gluing and stapling later.

Custom Capri overhead console

Switches mounted.

Custom Capri overhead console

Milling the various pictogram plates.

Custom Capri overhead console

I made a couple of spares in case I accidentally brake or scratch them.

Custom Capri overhead console

Time to start with the soldering. I am using red/green LEDs.

Custom Capri overhead console

Everything in the shrink wrap.

Custom Capri overhead console

What’s next!?

Custom Capri overhead console

A bunch of other wiring.

Custom Capri overhead console

Data connector, also wires in the shrink wrap, because I like to have redundant everything.

Custom Capri overhead console

Custom pictograms were designed and printed on a vinyl sticker, I also glued one of the top of the other so the back-light won’t protrude trough the black part.

Custom Capri overhead console

Some more prep work.

Custom Capri overhead console

Unit fully assembled. However, the power connectors were switched with the better ones.

Custom Capri overhead console

A detail.

Custom Capri overhead console

Cover plate removed.

Custom Capri overhead console

Detail of the wiring.

Custom Capri overhead console

Unit with the cover plate installed.

Custom Capri overhead console

A connector detail.

Custom Capri overhead console

Trying to figure out which wire goes where.

Custom Capri overhead console

Wrapping cables.

Custom Capri overhead console

Everything ready for the installment.

Custom Capri overhead console

At this point, the car is currently in the museum, so I’m making my mess there.

Custom Capri overhead console

Tight fit with a bunch of short wires.

Custom Capri overhead console

Good thing the windshield is out, makes the work much easier.

Custom Capri overhead console

Pictograms switch from red to green when activated.

Switching the lights.
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