{"id":66414,"date":"2019-05-29T22:03:29","date_gmt":"2019-05-30T05:03:29","guid":{"rendered":"https:\/\/www.ponoko.com\/blog\/?p=66414"},"modified":"2019-08-13T13:45:07","modified_gmt":"2019-08-13T20:45:07","slug":"custom-corvette-sound-system-enclosure-comvette-project","status":"publish","type":"post","link":"https:\/\/www.ponoko.com\/blog\/maker-success-stories\/custom-corvette-sound-system-enclosure-comvette-project\/","title":{"rendered":"Spot The Laser Cut Parts In This Car"},"content":{"rendered":"\n
\"Comvette<\/figure><\/div>\n\n\n\n

How The Comvette Project Uses Acrylic For A Seamless And Professional Finish<\/h2>\n\n\n\n

Look closely at the dashboard of this vintage Corvette. Now look again. Can you spot which parts were laser cut<\/a>? Unless you\u2019re a fourth generation Corvette (C4) aficionado, probably not. <\/p>\n\n\n\n

And that\u2019s by design. Wes Westhaver, a software developer\nwho leans toward software\/hardware integration projects, says he \u201cwanted to\nbuild something that integrated into the car so well that only an experienced\nCorvette owner would notice that it wasn\u2019t original equipment.\u201d<\/p>\n\n\n\n

So\u2026what is actually laser cut? <\/p>\n\n\n\n

It\u2019s the panel surrounding the sound system as well as the hidden chassis that holds all the components together. And it\u2019s all done with acrylic<\/a>.<\/p>\n\n\n\n

Seeing Opportunities For Improvement<\/h3>\n\n\n\n

Back when these cars were built (1984-1989), 90% of the 206,218 Vettes that rolled off the factory floor were tricked out with state-of-the-art BOSE sound systems. Rightfully so. Obviously, you can\u2019t listen to Whitesnake<\/a> without turning it up to 11.<\/p>\n\n\n\n

But time hasn\u2019t been kind to these tape-decks of old. Parts\nare hard to find if not altogether unavailable for the BOSE head units, and\nlocating someone with the skills to fix the system is almost as difficult and\nis woefully expensive. That is if you actually want<\/em> a tape deck. Most people fancy the new head units that offer\nAM\/FM stereo tuners, CD\/DVD players, backup cameras, GPS navigation and auxiliary\ninputs.<\/p>\n\n\n\n

To make the issue even more complex, the 1.5-DIN form factor\nthat GM chose to use is not a popular one with aftermarket manufacturers. With\nthe non-existent selection for drop-in replacements, there are a couple options\nfor incorporating a new sound system. One is to install a 1-DIN system, which\ntypically lacks a touch-screen and requires filler plates to hide the unused\nspace above and below the head. The other is to surgically cut up the dashboard\nso you can shoehorn a 2-DIN system into the 1.5-DIN opening to get the\ntouch-screen and video playback that you really want.<\/p>\n\n\n\n

Not happy with either option, Wes went to work finding a\nbetter solution.<\/p>\n\n\n\n

Designing A Better Fit<\/h3>\n\n\n\n

Wes began addressing the issue of replacing the outdated BOSE system with current technology, but he had to do it in a way the left the dash intact. It was clear that whatever kind of electronics enclosure<\/a> he designed would have to work within the space constraints of the 1.5-DIN form factor, especially because he had a big wish list of items he wanted to incorporate over time:<\/p>\n\n\n\n

* FM stereo radio
\n* MP3 audio player
\n* MP4 video player
\n* WiFi connectivity for loading MP3\/MP4 media
\n* Cellular connectivity for internet access on the road
\n* OBD1 diagnostics display and data logging (in progress)
\n* GPS flight recorder (in progress)
\n* Sport seat recliner and bolster control
\n* Dash-Cam recorder
\n* Backup camera<\/p>\n\n\n\n

\u201cMy foremost priority was to build a unit that blended with\nthe \u2018F-14A Tomcat\u2019 design aesthetic of the early C4\u2019s and has today\u2019s technology\ninside,\u201d he says. \u201cAnd no dashboard hacks!\u201d<\/p>\n\n\n\n

That\u2019s how the Comvette Project was born.<\/p>\n\n\n\n

Creating A Professional Finish<\/h3>\n\n\n\n

The chassis components for the Comvette Project are\ncustom-designed acrylic pieces that exactly fit the dashboard cavity used by\nthe original sound system. The electronics consist of readily available\noff-the-shelf parts, and the software is written in Xojo. <\/p>\n\n\n\n

In order to replicate the professional finish of the front\npanel and seamlessly integrate it into the dashboard so that it\nwas indistinguishable from the original parts, material selection was\nparamount.<\/p>\n\n\n\n

\u201cI chose black-on-white acrylic<\/a> for the front panel because it blended well with the interior of the car and could be engraved with text in a typestyle that matched the fonts used elsewhere in the dashboard,\u201d Wes says.<\/p>\n\n\n\n

\"Comvette<\/figure><\/div>\n\n\n\n

In addition to having the right\naesthetics, two-color acrylics are great for this type of application because\nthey are more durable than standard acrylics as they are less brittle and have\nmore flex, plus the 1.5mm thickness allows for buttons to come through easily. But\nwhat makes two-color acrylics attractive (literally and figuratively) is how\nthe engraving showcases the second color, giving excellent contrast and\nreadability to graphics or text, such as the \u201cvolume\u201d inscription shown above. <\/p>\n\n\n\n

In order to support the technology, Wes chose a Raspberry Pi\nrunning Linux. \u201cThe heart of the system is the popular Raspberry Pi\nmicrocomputer, which handles the audio, video and controls various components\nin the car such as the electric antenna, and power amplifiers,\u201d he explains. \u201cAnd\nthe benefit of having a Linux based computer at its core is that it can be customized\nin ways not yet imagined,\u201d he says.<\/p>\n\n\n\n

He housed all the components in a clear acrylic<\/a> enclosure for its functionality, easy visibility (handy during assembly) and affordability. <\/p>\n\n\n\n

\"Comvette<\/figure>\n\n\n\n

\u201cIn the past, I’ve contracted with metal fabricators to have\nvarious chassis components made, but the setup, labor and material costs are\nprohibitive for smaller builds like the Comvette Project,\u201d Wes explains. \u201cLaser\ncut acrylic, on the other hand, is ideal for projects like mine and was\nactually my first choice. In fact, laser cut acrylic has opened the door to\nmany projects that would have been too costly to pursue in the past because\nthey would have required sheet-metal fabrication.\u201d<\/p>\n\n\n\n

Working With Ponoko<\/h3>\n\n\n\n

It\u2019s safe to say that Wes is no stranger to building engineering projects<\/a>. \u201cI started disassembling my toys many years ago (much to my parents dismay) and eventually learned how to assemble them again (to my parents delight),\u201d he says. \u201cI\u2019ve made a career out of fixing, building and enhancing things.\u201d<\/p>\n\n\n\n

To expand his manufacturing acumen, Wes took a one-day class\nat a local community college to learn how to use the laser cutter in its\nfabrication lab. \u201cThe knowledge I gained there helped me understand the process,\nbut after finding Ponoko and seeing the online ordering process and the prices,\nI decided to give it a try.\u201d<\/p>\n\n\n\n

But that first order wasn\u2019t without a tad bit of trepidation.\n\u201cI have to admit, I was a little anxious when I placed my first order, but when\nI received the parts I got a wonderful feeling seeing something that I had only\nimagined now existing in the real world.\u201d<\/p>\n\n\n\n

Having confidence that the manufacturing side of his project\nis covered, Wes can focus on what\u2019s most important. \u201cI’d much rather\nconcentrate on developing my projects and let Ponoko handle the laser cutting\nfor me,\u201d he says.<\/p>\n\n\n\n

\"Comvette<\/figure><\/div>\n\n\n\n

Wes notes that the material selection<\/a> was one of the features that initially attracted him to Ponoko. Thanks for noticing! We put in a lot of hard work finding, testing and introducing new materials<\/a> each month so you not only have variety for your projects but also so you don\u2019t have to guess about what works great with laser cutting (or what doesn\u2019t).<\/p>\n\n\n\n

But what keeps Wes coming back? \u201cYour high quality and low\ncost are super important to me,\u201d he says. \u201cBut your quoting and ordering system\nis my favorite.\u201d<\/p>\n\n\n\n

To get all the details on the Comvette Project\u2014and check out the open source files\u2014visit the website<\/a>.<\/em><\/p>\n","protected":false},"excerpt":{"rendered":"

How The Comvette Project Uses Acrylic For A Seamless And Professional Finish<\/p>\n

Look closely at the dashboard of this vintage Corvette. Now look again. Can you spot which parts were laser cut? Unless you\u2019re a fourth generation Corvette (C4) aficionado, probably not. <\/p>\n

And that\u2019s by design. Wes Westhaver, a software developer
\nwho leans toward software\/hardware integration projects, says he \u201cwanted to
\nbuild something that integrated into the car so well that only an experienced
\nCorvette owner would notice that it wasn\u2019t original equipment.\u201d<\/p>\n

So\u2026what is actually laser cut?<\/p>\n","protected":false},"author":58,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1066,5796],"tags":[],"class_list":["post-66414","post","type-post","status-publish","format-standard","hentry","category-maker-success-stories","category-design-ideas"],"yoast_head":"\nSpot The Laser Cut Parts In This Car<\/title>\n<meta name=\"description\" content=\"With this custom electronics enclosure build, see how the Comvette Project uses laser cut acrylic for a seamless and professional finish.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.ponoko.com\/blog\/maker-success-stories\/custom-corvette-sound-system-enclosure-comvette-project\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Spot The Laser Cut Parts In This Car\" \/>\n<meta property=\"og:description\" content=\"With this custom electronics enclosure build, see how the Comvette Project uses laser cut acrylic for a seamless and professional finish.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.ponoko.com\/blog\/maker-success-stories\/custom-corvette-sound-system-enclosure-comvette-project\/\" \/>\n<meta property=\"og:site_name\" content=\"Ponoko\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/pages\/Ponoko\/34020780272\" \/>\n<meta property=\"article:published_time\" content=\"2019-05-30T05:03:29+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2019-08-13T20:45:07+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.ponoko.com\/blog\/wp-content\/uploads\/2019\/05\/Comvette-Project-1.jpg\" \/>\n<meta name=\"author\" content=\"Lisa Horn\" \/>\n<meta name=\"twitter:card\" 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