for any of ya'll who have custom cut plexi/lexan stereo trim (good post!)
 

Eh.

I am working on that right now. Using 3/16" Lexan, which you cannot score with a knife and then snap clean like plexi. I cut the interior stereo cutout with a dremel w/ cutting bit. It's ok, but not exactly perfectly straight like I want it to be. I'm thinking about trying again for perfection (it was a damn pain in the ass, but wait till you see it.)

Any advice on cutting an interior DIN sized cutout onto a piece of Plexi/Lexan. It seems like with Plexi, I could maybe drill four holes at the corners, cut the small sides, then cut a rough cut down the middle of the cutout, then score the long dimensions and do my best to snap em clean like you normally cut plexi. I used Lexan at first because I thought it would have better UV/ heat resistance (Texas heat.)

One more thing. There is some "dead space" below the cd player. I was thinking of masking off the name of my car on the back of the lexan panel before I spray it black. Then I would get some amber plastic, and put one or two bulbs back there to backlight "The Mound" in a nice font. It would match the color of the dash illumation.

Cool, or clownshit?

Could be cool ... use plexi it will work fine. Take your time masking off the text so it will look right when you paint it.

Definitely don't use Lexan, it doesn't break, but it scratches like CRAZY.

The second part about the cd player space sounds cool,

Since you already have a dremel you could get the attachment for it that is like the rotozip thing. You know, the rotary saw. Then you don't need to drill it at all. Just draw the lines on and plop the bit in and follow the lines.

why not make it using fibreglass?

get some plaster
get some pam spray oil and vaseline, take your original surround, coat the thing with pam oil and vaseline.

pour plaster, set srround in mold. wait for paster to cure remove surround. Then take carnuba wax... lots! and paint it into the mold. let dry

place fibreglass fibres in. make sure u use gloves and mask! pour the resin ontop of the fibres that were placed in mold.

wait to dry. trim to perfection.