Department of the interior, Department of the Car Interior, Console Supplies, 4wd Storage Drawers, Storage Drawers, car interiors, centre roof console, custom built console, floor console, roof console, overhead console, 4wd shelf
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INSTRUCTIONS ON INSTALLING A RADIO
INTO A CONSOLE

PLEASE NOTE! We strongly recommend, if the dimensions are available, that you pay a little extra and have any holes cut in the frame of the console before it is upholstered. Hole cutting prices (floor consoles, dashboard pods or roof consoles) are for cutting a hole in the frame ONLY. If you have purchased a console with the holes cut in the frame, when fitting the radio start at step 11.

Our custom built consoles have a plywood frame upholstered with a padded vinyl, velour or leather trim. Where possible a non structural 3mm ply facia panel is built into the console. This makes it possible to cut a hole from the inside of the console without removing the trim. In other areas, (e.g. the side of some centre roof consoles) the console is constructed of 10mm or 12mm plywood. In this case you must peel back a portion of the trim to cut a radio hole. For a neat fit, all holes should be cut to allow for a vinyl thickness on each side of the hole (see the chart for hole sizes). This allows for the vinyl to be folded around inside the radio hole, then stapled or glued for a professional finish. WARNING! Do not attempt to drill through the trim. The foam rubber can wrap around the drill bit and ruin the trim.

STEP 1. Make sure the radio to be fitted is no longer than the area allocated inside the console. If it is a floor console, ensure that the radio can be positioned so that it does not foul the heater, the dashboard or the transmission tunnel. If you are fitting a CB radio, check measurement "TD". A shorter, 90 degree angle antenna plug can be purchased for your CB if required.

STEP 2. Accurately measure your radio and write your measurements on the appropriate sketch. Click here for more info.

FOR SPINDLE TYPE RADIOS ONLY
The radio facia panel will cover the holes cut into the console facia. You can cut your radio hole through the plywood and the trim at the same time. The "cut - outs" should be the same size holes as in the radio facia panel. (i.e. cut holes for the nose piece and spindles only, measurements NH, NW & SW click here).

STEP 3. Cut a cardboard template to suit your radio size from a breakfast cereal packet or exercise book cover. The hole must be larger than the radio - see the chart for hole sizes.

STEP 4. If you are cutting the radio hole into a 10mm or 12mm plywood, remove the staples fixing the trim to the console in the appropriate area. This portion of the trim and foam rubber must be peeled back to allow you to mark and cut the hole. Use a paint scraper to separate the foam rubber from the console frame.

STEP 5. Position the cardboard template on the console. Ensure that it is sitting square and that the template is centred across the facia panel (if applicable). If you are fitting a CB with a side mounted microphone socket, position your template to allow enough space for the microphone plug.

STEP 6. Using a sharp pencil, mark a line around the template. If cutting 10mm or 12mm plywood, go to step 9.

FOR SPINDLE TYPE RADIOS ONLY
After marking out the holes for the nose piece and spindles, cut the holes out with your Stanley knife, jig saw or fret saw. If you find it easier, cut through the frame and the trim at the same time. Place the radio inside the console, then press the nose piece and spindles through the holes in the console. Attach the radio facia panel onto the radio from the outside of the console. Attach the radio strap supplied - see step 13 diagram "B". Then go to step 15.

STEP 7. Starting with very light strokes, run your specially prepared Stanley knife blade along the pencil lines. Gradually increase the pressure of each stroke until you have cut through the ply. Use a stabbing action to cut through the ply in each corner. Be careful not to cut the trim.
How to prepare your Stanley Knife for cutting the hole in a 3 mm plywood facia panel

Glue the piece of three ply supplied with the radio fitting kit onto the blade (with Araldite or similar) to prevent the blade from piercing the trim.
Clean any oil off the blade with methylated spirits before applying the glue.

STEP 8. On the outside of the console, firmly press the trim to remove the plywood "cut - out". Clean up the edges of the hole, firstly with your Stanley knife, then finish off with a steel file. Go to step 10.

STEP 9. If you are cutting the radio hole into 10mm or 12mm plywood, peel back the trim and foam rubber, holding it back with masking tape or similar. Cut the hole up to the outside edge of the line with a jig saw or fret saw. File the hole for a smooth finish. Glue the foam rubber back onto the console frame. Cut the foam rubber flush with the edges of the radio hole. Go to step 11.

STEP 10. Now the hole is cut in the console frame, you need to cut a hole in the foam rubber by lightly running a sharp Stanley blade along the edges of the hole (being careful not to cut the trim). Cut approximately 3/4 of the way through the foam rubber, flush with the edges of the radio hole. Using your fingers, pull the piece of foam rubber out of the hole. Clean off any small pieces of foam rubber protruding inside the hole.

STEP 11. Cut the trim as indicated by the following diagram. Be careful not to cut too close to the corners.

STEP 12. Staple or glue the four vinyl flaps onto the inside of the console. Make sure the edges of the hole appear straight and neat before progressing to step 13.

VACUUM MOULDED VINYL CONSOLES ONLY
If you are cutting a radio hole out of a vacuum moulded vinyl covered console (e.g. GQ Patrol, Maverick, Range Rover or Hino dashboard pods), before folding the four flaps back inside the radio hole, gently heat them with a hair dryer or heat gun. This will make it easier to fold the stiff vinyl around the plywood facia. The heat will also allow you to press the vinyl closer into the corners of the radio hole. Hold the vinyl in position until it cools. Then gently re-heat the vinyl in the corners. Push the front of the radio into the radio hole from the outside of the console. After the vinyl cools, remove the radio and go to step 13.

STEP 13. Open the radio fitting kit supplied with your console. Attach the radio strap to your radio as indicated in the following diagram.
A. Bend the radio strap to match the shape of the inside of the console. B. Bend the radio strap to butt up to the
25mm x 25mm wooden support inside the console.

STEP 14. Place the radio inside the console, gently pushing the radio into the hole that you have cut. Be careful the vinyl does not catch on the front corners of your radio. Use a blunt table knife to stretch the vinyl around the corners of your radio as you are pushing the radio into position. (NOTE: If your radio facia panel is larger than the case size the radio must be pushed into the console from the outside. In this instance you should attach the radio strap after pushing the radio into the console).

STEP 15. Ensure the radio is sitting square to the console and protruding evenly from the console facia. Fix the radio strap securely to the console using the 12mm 10 gauge self tapping screws supplied. If your radio is the same as in diagram A, step 13, when fixing the radio straps to the console, use two self tapping screws on each radio strap.


CHART FOR RADIO HOLE SIZES

Note: This chart does not apply to spindle type radios

YOU MUST ADD THE AMOUNT SPECIFIED TO YOUR RADIO MEASUREMENTS.

THE MEASUREMENTS SHOWN IN THIS CHART ARE AN EXAMPLE ONLY.

FOR LEATHER TRIM, ADD AN EXTRA 1mm TO THE CARDBOARD TEMPLATE MEASUREMENTS SHOWN IN THIS CHART.

For the prices to cut holes, supply and / or fit speaker grills, CB extension speakers etc, click here (floor consoles, dashboard pods or roof consoles)


INFORMATION REQUIRED TO CUT A HOLE IN A CONSOLE FOR A CB RADIO
1. Accurate measurements in millimeters of the case size behind the facia panel. Also the measurement from the back of the facia panel to the back of the antenna plug (part No. PL259. NOTE: the antenna plug must be attached to the CB to obtain measurement "TD").

2. Position of microphone socket on the CB case. Is it on the left side, the right side or the front as you look at the face of the CB radio. (NOTE: If the microphone socket is located on the side of the CB and you are fitting the CB into a low profile or deep profile centre roof console, then in most cases it will be neccessary to cut a hole in the side of the console to accept the microphone plug. We strongly suggest, in this instance, that you have the holes cut in the frame of the console before it is upholstered.)

3. Position of the speaker on the CB radio. Is the speaker on the front facia, the base, or the top of the CB ? Does the CB have an extension speaker socket? If the speaker is on the base of the CB, do you require a speaker grill or an extension speaker ? (our extension speaker is 8 ohms, 4 watts)

4. Make and model of CB radio.

INFORMATION REQUIRED TO CUT A HOLE IN A CONSOLE FOR A RADIO, CD, CASSETTE PLAYER, AMPLIFIER, EQUALISER, DIGITAL CLOCK ETC.
PLEASE PROVIDE ACCURATE MEASUREMENTS IN MILLIMETERS

For the prices to cut holes, supply and / or fit speaker grills, CB extension speakers etc, click here (floor consoles, dashboard pods or roof consoles)