Black 5 Turbo Project

[Phoenix Autosport]

my 5 pretty much OE needs the odd bit of tlc but basicaly sound and rust free
http://www.phoenix-autosport.co.uk/images/side.jpg

http://www.phoenix-autosport.co.uk/images/front_right.jpg

http://www.phoenix-autosport.co.uk/images/rear_right.jpg

http://www.phoenix-autosport.co.uk/images/rear.jpg

not going to mod the hell out of it just restore and update sympatheticaly :)

[Phoenix Autosport]

made a start on my centre console, put the original one into storage in case i want to change back at any time in the future and started work on a new one.
basicaly im going to graft in a mk1 clio stereo cover to hide the more modern stereo from prying eyes.
how cover looks in the open position
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/563473_356475647732771_265290366851300_997710_7343 0068_n.jpg

and how it looks closed
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/529909_356476357732700_265290366851300_997711_2130 51717_n.jpg

first thing was to remove the plate sticking up at the back as this will just get in the way going into the 5
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/553042_356477231065946_265290366851300_997712_1885 092771_n.jpg

top edge finished neatly and straight with a sanding block
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-prn1/524444_356478177732518_265290366851300_997713_8484 36153_n.jpg

view from the back, the top edge of this will fit against where the bottom of the ashtray screws in in the 5
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/539244_356478837732452_265290366851300_997714_2196 08808_n.jpg

because the fixings for the ashtray are recessed a spacer was made from a couple of layers of plastic bonded together and shaped to fit into the recess, 1mm pilot holes were drilled in the correct place for the fixings
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/558558_356479777732358_265290366851300_997715_6745 08922_n.jpg

after trial fitting into the car to get positioning correct the spacer was bonded to the clio stereo cover pilot holes were drilled through into the cover and pegged with wire to keep allignment right
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/533485_356480014399001_265290366851300_997716_1346 482747_n.jpg

top edge was finished flush
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/526544_356480221065647_265290366851300_997717_1110 411991_n.jpg

the first of 2 donor centre consoles, this one will form the basis of the new console it came from ebay with a broken top mount but as this is not needed the bargan price was a plus
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/564697_356480324398970_265290366851300_997718_2081 711239_n.jpg

console now cut out for ready for grafting in the clio stereo flap, as this will sit slightly forwards of the original possition the switches will also need to move forwards so the mountings are cut out and will be relocated later
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/551862_356480447732291_265290366851300_997719_9271 80246_n.jpg

front on view of the console
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/548547_356480627732273_265290366851300_997721_1630 711194_n.jpg

after fitting the console into the car and offering the clio cover up to the ashtray mounting point the 2 were tacked together to ensure correct possitioning
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/389725_356480724398930_265290366851300_997722_1895 694881_n.jpg

rear view showing pieces of plastic temporarily tacked in to hold position correct
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/556052_356480897732246_265290366851300_997723_2016 061848_n.jpg

the second centre console, again an ebay find in with a job lot of other parts had holes cracks and front vents broken out and has been sprayed with black dye but will do nicely as a donor to take sections from, the front section was cut out for grafting into the new console to form a new front edge
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/551653_356481017732234_265290366851300_997725_6188 57316_n.jpg

section was trimmed to fit and cut in half as moving it forwards requires it to be a couple of mm narower side to side, pic shows first side bonded into place, note a strip has also been bonded in the back edge of the switch hole as the front section will fit to this area, also the sides of the clio cover has been cut away as the sides will need to be reconstructed to match the lines of the console
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-prn1/555958_356481117732224_265290366851300_997727_4342 95716_n.jpg

close up of the first section grafted in
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-prn1/557146_356481264398876_265290366851300_997728_1503 757704_n.jpg

will post more as work progresses or you can click like on facebook to be kept up to date on this and all our other projects http://www.facebook.com/phoenixautosport

[Tony Walker]

:agree: Nice mod

[Phoenix Autosport]

did a bit more on the centre console today, starting to take shape now :)

plate bonded inside to provide a base
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/533457_358246654222337_265290366851300_1003851_151 2821656_n.jpg

section cut from the other console bonded on to form the side also a plate bonded inside along the front to add strength
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/318222_358246730888996_265290366851300_1003852_149 4432059_n.jpg

plate on side filled with cyanoacryalate and finished to shape inc fine filling of some of the previous parts
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-prn1/544972_358246820888987_265290366851300_1003853_169 449_n.jpg

next section of side bonded in place along with another strengthening platre inside
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/582070_358246910888978_265290366851300_1003854_148 9444107_n.jpg

right hand front section bonded in place
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/582080_358246994222303_265290366851300_1003855_158 2296666_n.jpg

switch panel section was cut from the other centre console along with the curved side profile as i want to angle them slightly so that it leads into the stereo area rather than there being a big step up to it
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/582446_358247077555628_265290366851300_1003856_632 105731_n.jpg

section was cut out and replaced with part from the other consoles switch area in order to form an extra 2 switch locations for a future mod
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/549253_358247140888955_265290366851300_1003857_209 3131380_n.jpg

plates bonded front and back to strengthen the join between the parts
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/295108_358247217555614_265290366851300_1003859_972 524242_n.jpg

5 switch recess ready to fit
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/385589_358247327555603_265290366851300_1003860_413 478264_n.jpg

switch panel tacked into place
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/555514_358247424222260_265290366851300_1003862_143 238084_n.jpg

front view of switch panel tacked in place
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/536263_358247554222247_265290366851300_1003863_180 3478623_n.jpg

switch panel bonded in all round on front and back and skim filled to get final shaping
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-prn1/535606_358247644222238_265290366851300_1003864_457 883978_n.jpg

[Phoenix Autosport]

started work on the other side of the console
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/309957_358868037493532_265290366851300_1005337_208 4235776_n.jpg

got the right hand side up to the same stage as the left, also filled the top sides either side of the stereo opening with cyanoacryalate to make them good and solid, gone over the entire front end filling any joins, nicks and screw holes from a previous owners additions, then sanded everything forwards of the stereo opening to give a good base for the flock to adhere to
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/564508_358868117493524_265290366851300_1005338_751 058523_n.jpg

[TOMTOM]

Looking great fella. Be nice to see once u finished it:)

[Tony Walker]

cant wait to see it flocked. Geussing thats where your going with it?

[Phoenix Autosport]

cheers guys, yes it will be flocked in the grey i use on the door cards once i have finished the back where it meets the dash

[Phoenix Autosport]

trial fitted the console to check the back edge as i had to alter the angle of the top section slightly to keep the stereo angle correct so as to miss the heater assembly, as i expected this has left a gap at the back of about 3mm so i will have to fit a plate along the back then refit the part that fits the recess where the astray fixings are
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/536789_359581937422142_265290366851300_1006783_192 0984243_n.jpg

how it will look with the cover in place
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/533275_359582010755468_265290366851300_1006784_538 336311_n.jpg

[Tony Walker]

v nice, v oe :D

[Phoenix Autosport]

in order to rectify the small gap between the rear of the stereo surround created when i had to angle the surround to avoid the stereo hitting the heater assembly behind where it fits the rear edge needed remodeling, to do this i first removed the locating piece i had previously fitted on the back and sanded back the surface so that a plate could be bonded on to it to fill the gap
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/528004_360807857299550_265290366851300_1009565_152 2034229_n.jpg

plate now bonded in place left slightly oversize so that it can be finished flush along top and sides once the sides have been finished
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/524257_360807913966211_265290366851300_1009566_142 3726662_n.jpg

locating holes were drilled through from the front so that the locating piece could be refitted in the correct position again using wire guides
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/540409_360807970632872_265290366851300_1009567_190 6131154_n.jpg

both sides were completed structuraly with plastic and sanded to shape
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/548477_360808063966196_265290366851300_1009568_156 1574450_n.jpg

fine filling done to give final surface smooth for flocking
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/405129_360808140632855_265290366851300_1009569_818 831197_n.jpg

to prepare the cover flap the plastic section was first removed from the metal frame
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/530437_360808233966179_265290366851300_1009570_761 616695_n.jpg

to allow for the extra thickness of the flock coating whilst allowing the flap to operate smoothly without catching i removed approx 1.5mm from each side of the flap using a sanding block
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/553802_360808303966172_265290366851300_1009571_122 5528138_n.jpg

edges were then reshaped to get rid of the sharp corners and restore the original shape, also the surface was keyed ready for flocking
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/549296_360808400632829_265290366851300_1009573_112 5496247_n.jpg

like most renault 5 centre consoles the mounting lugs had seen better days and whilst they were still functional with washers i decided to sort them before they got any worse
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-prn1/522696_360808473966155_265290366851300_1009574_807 922915_n.jpg

plates bonded in place to the top of the damaged mountings and slots made using a dremmel and a small milling cutter
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/563144_360808563966146_265290366851300_1009575_114 8694147_n.jpg

[Nad-5GTT]

Some good work going on there, im very impressed. Keep the pics flowing

[Phoenix Autosport]

43) opening the flap by hand would just be far to 1991 for my liking so im mounting a servo to do the job for me, bracket has been made from a section of plastic crafted to fit the underneath of the back where the flap stowes when open
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/564355_366084070105262_265290366851300_1020902_136 926386_n.jpg

44) bracket will be bonded into the console once link rods etc have been made to the correct length, extra blocks have been glued on where the screws fit to give them a good thickness to fit into securely
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/399123_366084193438583_265290366851300_1020903_658 685334_n.jpg

45) shaped control rod made from plastic, this may be changed for metal at a later date but for development purposes its far easier to cut, bend, glue and modify a bit of plastic to get the right shape and length, proper fixings are substiuted with wire at the moment to allow me to pull apart and put back together in second rather than minutes
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/303307_366084293438573_265290366851300_1020904_413 656969_n.jpg

46) slot at the back of the surround cut to allow the control rod to pass through
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/399105_366084356771900_265290366851300_1020905_700 453738_n.jpg

47) rods attached and servo/bracket held into place at this point the final servo attachment hasnt been made so there is a rod joining the servo centre point and the arm to allow me to work out where parts will fall as the servo moves and determine the angles of movement required
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/544839_366084490105220_265290366851300_1020907_553 480891_n.jpg

[Tony Walker]

Fantastic :agree: black nail varnish is a bold statement tho :p

[Phoenix Autosport]

Fantastic :agree: black nail varnish is a bold statement tho :p
:rolleyes: i knew someone would spot that, its vinyl cote from spraying the some parts, bloomin stuff comes off your skin but any you get on your nails wont budge, now i keep getting dodgy looks from people.
note to self wear gloves next time :cry:

[Phoenix Autosport]

48) servo bracket now fixed into place and arms trimmed to length to give the correct amount of movement, joints still pinned with wire at the moment until fixings arrive
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/545775_368133649900304_265290366851300_1027649_129 2386354_n.jpg

49) side view of mechanism
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/578686_368133756566960_265290366851300_1027650_171 5887292_n.jpg

SEE THE VIDEO OF TESTING THE SERVO MECHANISM HERE (http://www.facebook.com/phoenixautosport/videos)

http://www.facebook.com/phoenixautosport/videos

[Harri]

43) opening the flap by hand would just be far to 1991 for my liking [/IMG]

Yes, this is exactly the right spirit. IIt seems that in order to get these kind of accessories just buying a new car is not an option for most members here. Definetly nice addition to already good mod.

[djinuk]

attention to detail, friggin amazing, cant wait to see this mod completed

[Phoenix Autosport]

cheers guys, done a bit more today just to get the fit right, had to trim a few mm from the top of the bracket to clear the botton of the dash where the console slots into it and take the corner off the bottom of the bracket to clear the heater assembly but it all fits in now and operates without fouling on anything, got a week away this coming week so wont be any progress for a while but the console isnt far off being flocked now, giving it a uniform coating will show the shaping achieved rather than all the various materials used in its construction and make it look a whole lot neater

[Phoenix Autosport]

50) bottom right - small holes for springs that normaly hold the flap open or shut have been filled and sanded as they are no longer required. middle left mounting screw holes are also surplus to requirements
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403419_383773018336367_265290366851300_1067086_661 440002_n.jpg

51) screw hole shown from back top left of stereo opening
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/536388_383773151669687_265290366851300_1067087_732 21912_n.jpg

52) screw hole blanked with plastic on the back
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/525156_383773295003006_265290366851300_1067088_128 2900761_n.jpg

53) screw hole filled with cyanoacryalate from the front
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/163380_383773368336332_265290366851300_1067089_506 171468_n.jpg

54) filled screw hole ground back to a smooth finish using a small milling cutter in a dremmel
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/547300_383773445002991_265290366851300_1067090_143 167672_n.jpg

55) bracket for the servo was touching the heater assembly and lower edge of dash when fitted to car and would not allow the console to quite fit into place properly so the shape of the back edge was revised to give the required clearance
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/179737_383773561669646_265290366851300_1067091_168 8993021_n.jpg

[Big Steve - Raider]

WOW! :eek:

EPIC Work :niceone:

[TNT ANDY]

Great attention to detail.

[Phoenix Autosport]

56) areas that were modified have been etch primed so that any imperfections can be seen easily. all imperfections filled.
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/547571_386699511377051_265290366851300_1074468_152 7228827_n.jpg

57) sanded back and blown over sanded areas.
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/542182_386699628043706_265290366851300_1074469_875 547087_n.jpg


58) front view
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/533279_386699748043694_265290366851300_1074471_791 64770_n.jpg


59) top view
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/542936_386699864710349_265290366851300_1074472_553 031438_n.jpg


60) top mounting holes opened up to correct size for fixing screws, as these will locate where the bottom of the ashtray mounts the fixing screws will need to be conciderably longer than the originals.
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/379358_386699981377004_265290366851300_1074473_560 547071_n.jpg


61) holes countersunk so that screws can be fitted flush, as well as being neat this is also required to avoid the flap getting caught on the fixings.
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-prn1/522832_386700054710330_265290366851300_1074474_149 9913107_n.jpg


62) checking fixing sits flush
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/536002_386700161376986_265290366851300_1074475_771 04875_n.jpg


63) rear of console with fixings in.
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/75933_386700264710309_265290366851300_1074476_1239 441610_n.jpg

[Phoenix Autosport]

64) console now flocked
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-prn1/551151_387870044593331_265290366851300_1077578_562 387498_n.jpg


65) front view
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/579252_387870171259985_265290366851300_1077579_356 756833_n.jpg


66) close up of side
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/538121_387870264593309_265290366851300_1077580_193 0721731_n.jpg


67) flap re-assembled however best laid plans and all i didnt allow for the cover when i made the arm meaning it catches where the cover overhangs the bracket
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/559998_387870321259970_265290366851300_1077581_118 3397127_n.jpg


68) a little re-shaping to give some more clearance
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-prn1/545126_387870391259963_265290366851300_1077582_498 04832_n.jpg


69) now allows arm to move further to allow for the cover when fully open
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/536801_387870447926624_265290366851300_1077583_134 686638_n.jpg


70) all re-assembled
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/556160_387870584593277_265290366851300_1077584_388 804126_n.jpg


71) comparison to the original console with flap open
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/564278_387870707926598_265290366851300_1077585_393 976327_n.jpg


72) comparison to the original console with flap closed
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318293_387870854593250_265290366851300_1077587_193 8536081_n.jpg

[Phoenix Autosport]

And a video of testing the machanism all functions correctly after re-assembly

http://www.facebook.com/photo.php?v=387879984592337

[Big Steve - Raider]

That is just WIN! :niceone:

How will you operate the servo to drive the right amount on it's own?? :scratch:

[Alastair]

Very nice!

[Phoenix Autosport]

cheers chaps, the servo has a ground and regulated supply line and the position is driven by a pulse width signal so im building a controller so that i can switch on the power and apply one of 2 different preset pulse widths just by pushing a button so it will just be one button to open and another to close,

thanks to an ebay seller in china advertising as they were in the uk im still waiting on some of the parts for that though, its always the flippin parts isnt it :rolleyes:

[w35ty]

Loving that mate! Proper job there looks ace:agree:

[Phoenix Autosport]

well it was MOT time today and it failled, all because of a bloody tyre :mad:
looked just about legal to me but the MOT man was having none of it and the spare he reconed wasnt any better, of course no one carries them in stock either, i had ordered one a couple of weeks ago knowing it was low but it still isnt here, anyone local got one i can borrow just to put it through the MOT so i can get the tax sorted

[Phoenix Autosport]

a result, a loan of some wheelswith legal tyres from big steve and its now got an MOT again i had forgotten just how much attention it gets, had a bloke knock at my door within a couple of hours of bringing it home asking if i wanted to sell it :eek: i think he thought its got no tax on it so he could get it cheap, no chance mate :laugh:

[Trevhib]

Nice one. Now where are the pics with the console fitted? :D

[Phoenix Autosport]

i may put it in soon if i have time and get bored :laugh: but the interior is being stripped soon as its getting a minty set of raider seats and a black carpet when i install all the new stereo wiring and a few other wrinkles, just want to get all the bits ready so that im not spending the summer driving a car with no interior