Fitting a double DIN radio
I started out with the idea to fit a radio with a rear view camera option, then I thought that a few bucks extra would give me the navigation feature. Slowly the price of a unit went up as I saw extra features that I liked, I had started at the bottom of the Kenwood range and went up from there. I then saw refurbished units at considerable savings, I asked Pizzaguy who worked for JVC/Kenwood at the time what the word was on refurbished units, he looked into it and said they were as good as the brand new ones. So that is what I purchased a Kenwood DNX893S. CLICK
All the switches on the existing radio/AC face plate will be relocated to the cup holder face plate. The ash tray/ coin holder, passenger air bag light and the power outlet/cigarette lighter will stay where they are. The ash tray will be operable with some modifications as the rear would interfere with the radio unit. The rear of the ash tray assembly has to be sawed off so that it does not foul the units mounting frame. A cabinet opener will be attached to the rear of the ash tray unit to make it move forward enough for it to be opened by hand.
The existing single din radio opening will be enlarged to accept a double din radio. The removable frame that surrounds the Double Din unit in the face plate will fit snugly in the opening recess and allow access to the two screws that hold the radio/AC face plate in place. The head unit itself will hang from the roof of the single DIN opening in its sleeve and put no load on the face plate itself, getting it all to align will be the secret to a nice looking fit.
The layout shown is not suitable for a roadster as the roof switch area is used when extending the cup holder aperture, although this switch could be relocated.
The ability to work with hand tools is a must.
Parts required for this modification;
(2) Radio face plates.
(1) Cup holder face plate.
(1) Ash tray assembly.
Acetone
J-B Weld Plastic Bonder
Gorilla Super Glue
Bondo Glazing and Spot Putty
Hack saw blade holder.
Various files and drills.
Vernier, scales and layout tools.
Plenty of patience is definitely required.
The parts I have obtained to make my double din face plate and switch relocation modifications with.
The Kenwood DNX893S Radio with navigation. The screen is actually unmarked and black, the photo shows a reflection of the board.
With no power the screen slowly sags out as shown in the photo. The unit is unmarked, the shiny spots are reflections.
The unit is shown reversed in its mounting frame so it does not get locked in.
Removing the recessed switch portion from the first radio face plate. The bottom of the face plate has already been removed by cutting it off at the bottom of the recess.
The separated pieces.
Drawing showing how the trimmed to width switch plate (bezel) fits inside the lengthened cup holder bezel aperture. The cup holder bezel has an undercut in the aperture which is ideal to locate the new switch bezel in as seen in the drawing. The recessed switch bezel is trimmed in width to fit in the undercut and the ends are made square to the sides.
The existing aperture in the Cup Holder bezel will be extended so that the switch bezel fits into it. The extended aperture will entail cutting into the roadster roof button area.
The new switch bezel consists of two parts, the two halves are attached to one another with a cement. Not all of the matching faces are bonded together and my switch plate needed to be bonded in more places as it was in danger of falling apart at the moment. This could pose a problem as I am using a router to trim the switch plate width so that it fits into the cup holder aperture. I used acetone run between the touching faces and J-B Weld Plastic Bonder around the edges.
The switch plate trimmed to length and .02" oversize on the width. The front and back of it having been re-secured to each other.
Marking out the extension to the cut out in the cup holder bezel.
The plate ready for routing the profile.
The new switch plate bezel is shown fitted together, it will now be sanded down for painting, cemented together and the radii in the corners filled and blended. The original face plate from which the switch plate section was cut was from a 2004 Crossfire, this is evidenced by the shiny clear coat surface on the plate itself. The other parts have the later duller finish on them, a point to remember if replacing a silver interior trim part. I used a router to trim the sides and ends of the switch portion and the cup holder pocket parallel and square. I made up a simple jig to do this and a knowledge of routing is a must or you could cut yourself really badly. A file would be safer, but not as fast.
Article continues in post #2
Last edited by onehundred80; Mar 29, 2021 at 04:44 PM.
Reason: thread abandoned