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.
2. Accurately measure your radio and write your measurements on the appropriate
sketch. Click here for more info.
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).
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.
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.
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.
6. Using a sharp pencil, mark a line around the template. If cutting 10mm
or 12mm plywood, go to step 9.
SPINDLE TYPE RADIOS ONLY
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.
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.
to prepare your Stanley Knife for cutting the hole in a 3 mm plywood facia panel
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.
oil off the blade with methylated spirits before applying the glue.
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.
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.
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.
11. Cut the trim as indicated by the following diagram. Be careful not to
cut too close to the corners.
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
MOULDED VINYL CONSOLES ONLY
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.
13. Open the radio fitting kit supplied with your console. Attach the radio
strap to your radio as indicated in the following diagram.
Bend the radio strap to match the shape of the inside of the console.
Bend the radio strap to butt up to the
25mm x 25mm wooden support inside the
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).
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.