iPod mini custom install in my ford explorer

[reelmagik]

I decided to install my new iPod mini in my 2002 explorer sport. I removed the center console and sculpted a new piece that would fit right into it and house my iPod mini. I molded it with latex, backed with a plaster shell, then cast it in dental acrylic. I then sanded it, and painted it with a few layers of primer and about 4 colors of spray paint to match the interior, then topped it off with a few light mists of matte clearcoat. I added fiber optics to light up the front of it at night, and a jack to charge it while it sits in the car. The car charger is built right into the piece I made. All the wires are hidden beneath the console and I am currently trying to decide whether I want to add an audio cable that will retract to have the option of picking up the iPod while driving and still have the current song playing, or adding the remote control somewhere accesible, but still hidden.

The fiber optics are simply fiber optic cable I bought from a fiber optic retailer on the internet, and they run from the two holes in the piece, down under to two LED's that are powered via a third cigarette lighter adapter I added inside the center console. The two holes in the piece I made were topped off with a 50/50 mix of white and clear dental acrylic to give a softer glow from the lights.

The pictuer I included was before I hid the wire underneath the console.

[reelmagik]

Here is how it looks at night.

[reelmagik]

The piece and it's mold after it was cast in dental acrylic.

[reelmagik]

Painting in progress.

[reelmagik]

A closer look.

[reelmagik]

Here it is after I decided to hide the audio cable.

[reelmagik]

Another night shot just cause it looks so cool.

[AndrewHarrison]

that is ####ing cool!
i love the blue LED/fibre optics effect.
i am so jealous.

[RockPod]

Cool install dude! You did a great job on the custom mount and the blue lights look awesome.

Which charger did you use?

[reelmagik]

I used the BELKIN auto charger. I have to say that only one time since I have had it installed have I heard an engine whine coming through the speakers. It was very faint and only lasted while the ipod was NOT connected. When I reconnected it, the engine noise disappeared.

[somedevil]

This might be my favorite install as of yet. Simple, classy, totally custom. Nice job man. Where does one get materials like the ones you mentioned, plaster/dental acrylic, and how did you make the mold?

Edit: Oh, and total cost? I'm sure some people "me" would like to take on a project like this in the future, any tips would be appreciated?

[415 w210]

thats freaking bad ###. nice job.

[reelmagik]

Most of the supplies I used were from BURMAN INDUSTRIES, their online store is at:

http://www.burmanindustries.com/

They will supply the dental acrylic, if that is what you plan on using. They also carry a ton of other special FX supplies. There are other cheaper alternatives to dental acrylic. You can get 2-part plastics from either Burman or another online store called SMOOTH-ON: http://www.smooth-on.com/default.htm

They also supply SILICONE, for moldmaking, which is what I recommend. It is a 2-part chemical mix, which is fairly easy to use, but you need a separating agent to coat whatever it is you are molding. A silicone spray will work. The plaster can be obtained from my personal favorite store located in NEW YORK, called ALCONE THEATRICAL SUPPLY: http://www.alconeco.com/frame_popular.html

You want ULTRACAL 30 plaster and burlap to cut into strips for strength in the plaster backing. They also supply L-200 casting latex, which is what you want if you decide to make the mold out of that instead of silicone. The latex needs to be applied in layers, appoximately 20-30 thin layers, with some kind of strengthening agent applied between a few of the layers...paper towels soaked with the latex will work just fine. I strongly recommend the silicone process instead, it is quicker to apply, and you just need one thick coat of it.

You really need to have some sculpting/moldmaking/casting experience to make this work. If you have never tried anything like this before there is a good chance you could screw it up royally or even hurt yourself. Be careful and good luck.

[reelmagik]

Oh, the cost...it all depends on what products you choose to work with. I have all the materials I needed stocked up in my basement workshop, so I didn't have to buy anything for this project. I would estimate that the materials I used would have cost about $40-$50...but you also have to remember that you most likely will have to purchase more than you need, as things are sold by the pound, gallon, etc. You could easily spend close to $100 buying all the materials, but then you would have them to use in the future if you plan on making something like that again.

[tanakasan]

Hmm...dental acrylic, plaster, L200, ultracal, silcone molds, Burman, screen name=reelmagik...You must be an FX tech!

I am also in the biz, here in L.A. Its a lot of fun to apply the tricks of the trade to iPods!

Nice install! Clean, simple, cool. Did you use the dock inside?

p.s.
Thats a boat load of acrylic! Can you say "high" buddy?