Double to Single DIN Stereo Surround

Double to Single DIN Stereo Surround

Ford Focus Phase 1 Stereo Surround Conversion.

Tools Needed:

Wet & Dry - 320,600,800,1000,1200 gritt
Lollypop Sticks (trust me / Craft shop)
Bondo & Fiberglass resin
Small Possi and flat screwdrivers (watch makers type)
Primer
Paint
Laquer
Freezer Bags
Panel Wipe
Tack rags / blue roll
Cotton Wool Buds
Facia adapter panel (snap in)
Latex Surgeon's Gloves

Part 1:



This is what we have to work with. Now the eagle eyed of you will notice that once this project is finished the car will look a little diffrent, Thats because the Facia has been changed again (bloddy Mind Changing PR#ck). Also I dont have a pic of the oriningal one. so just forget about that little fact.

First we need to Strip all of the parts from the panel, or buy a new one (bout £20). Take the little draw out, cigarette lighter, clock etc and all the clips, put them all in a freezer bag and put safe for refit later. Once you have stripped and bagged, you need to clean like you never cleaned before.

Use Panel Wipe (brake & clutch cleaner / degreaser / at very worst Meth's), Blue Roll or tack rags, for the fiddly bits use cotton wool. You cant use enough panel wipe, it will just evaporate off any way. This is really important, you need to get rid of all that silicone build up from all of those interior shine / Instant shine pads and spray you have been using to make your interior shiny.

Once all that is off give the whole panel a once over with 320 gritt paper, only lightly, your not trying to smooth but key up the surface for thr next step.

Double to Single DIN Stereo Surround

Ford Focus Phase 1 Stereo Surround Conversion.

Part 2:

Ok next you need to get the Facia panel converter / mask (the black flat plate under the hazard light switch), these only cost a couple of quid from a motor factor, or if you have trouble you can order one from the BIG ORANGE AND BLACK shop or a well know auction web site. If that is no good give me a PM and I will get one for your car as I have a trade account with the company that makes them.

It should just push into the top part of the DIN hole and snap in with little clips on the back, once in it shouldn't move.
Grab your Bondo (Body Filler) mix up a batch as per destructions in pack, and cover the new Panel insert with the mix. You can try to shape it a bit before it goes off, but it sands easy enough. Leave this to dry for about and hour or so. If you touch the bondo and it fells warm or like heat is comming of it, DON'T PANIC, this is completly normal as the Mix is going through a chemical curing process and will warm up as part of this. once cold and hard you can begin to shape the bondo.

Repeat this step until you are happy with the finish. You need to get the bondo a smooth as possible. Use the Wet & Dry with clean water and work through the grits up to 1000.

Double to Single DIN Stereo Surround

Ford Focus Phase 1 Stereo Surround Conversion.

Part 3:

I did a further step after the bondo, due to a bit of movment I didn't want the bondo to crack. so I mixed up a fresh batch and mixed in some Fiber glass resin. This gives the effect of making the bondo alot stronger as it is lick impregnating it with plastic when it drys. I found this gave a very smooth finish and allot better adhersion.

Once happy. Grab the panel wipe and clean clean clean. Find someway that you not gonna get killed by you significant other and start spraying the Primer. Rattle cans are fine for this job as it is only a small area. Remember LOTS OF LIGHT COATS ARE BETTER THAN RUNS. Spray left to right or right to left and always continue spraying past the target. This should give you nice even smoot coats of paint.

Leave the primer to dry for at least half an hour between coats. If you start to see bubbles or swirls or the primmer spliting, then you need to sand it all back and start again. This usually means you have grease or oil on the panel and the paint is reacting to it, (clean clean clean)

After a couple of coats of primer, your facia should look something like the below pic.



Next up, MORE SANDING. Again use clean water and work through you Gritt levels untill smooth.

Double to Single DIN Stereo Surround

Ford Focus Phase 1 Stereo Surround Conversion.

Part 4:

Home stretch now. Once you are happy with the finish of the primer, Guess, go on guess, Clean clean clean. Grab your selected paint and start to spray, same as the primmer, lots of thin coats right to left or left to right build op the coats, at least half an hour between coats.

Once happy, wet flat again. If you want the perfect finish, you have to work at it. the smother the paint the smoother the laquer etc etc etc.
Also ORANGE PEEL looks horrible.

Laquer and wet flats etc etc etc and you should end up with some thing like below.

Double to Single DIN Stereo Surround

Ford Focus Phase 1 Stereo Surround Conversion.

Part 5:

At last you Got there. Grab that freezer bag full of bits and start to refit everything back into your facia, and refit to the car.




Obviously this job was done on a Focus, but the process is exactly the same for any interior panel that you want to flush or simply colour code. I hope this has been helpfull, check out our other "HOW 2 Guides" for other projects and if you get stuck then just get in touch. Dont forget I run a Custom Car company and can help with jobs, parts and supplies so just ask.

Thanks for Reading

Happy Modding

The Bishop