I wanted a dual gauge pod that fit below the HVAC controls in my GTI. I figured I could relocate the power outlet to the armrest cubby since that's where my Audio input is. One company already makes a similar design, but it's $150!!! That's more money than I want to pay. So I decided to design my own and have it lazer cut.

This is a WIP, but I should finish soon

Step 1: Design your gauge pod. I used Google Sketchup to design my pod in 2D, then extracted it and built it to see how it'd look with 4.5mm Acrylic or PETG.



Step 2: Export the design to EPS and modify it in illustrator so that it fits on a template provided by ponoko. Ponoko is located in New Zealand but shipping is only $15 and they'll lazer cut 3 of these things for $20 or so. My total cost after shipping was right around $35. Make sure when you get it cut that you pick the right thickness. I used 4.5mm Acrylic because I wanted to do some etching. It's more fragile, but on such a small piece it's fine. Especially since the gauges actually give it a nice structure.

Step 3: Receive the cut pieces from Ponoko and do a test fit in your car. (You'll notice I had GTI etched on the front, I did a few different designs because I ordered 3 sets).


Step 4: Assemble the pieces and secure them with some epoxy glue to fill in the cracks. Let dry and sand down any major issues. Then apply some bondo on any visible cracks and sand again. Paint/sand/paint/sand/paint/sand until it looks nice.





I still need a a coat or two more and some more sanding but it started raining outside where I was painting. Anyway, here's the progress so far. Not bad for under $50?




Step 6: (which I haven't finished yet)... assemble all the wiring and stuff and install it under the HVAC controls. You can do this using the screw holes and a bolt/washer by removing the radio to gain access, or you can use double sided tape... I haven't tried either yet so I don't know how it's going to work. I'll post updates when I finish.

You can download the design at Ponoko, just click here!

My first major mod of the GTI will come this weekend (hopefully). Russ@Raderwerks is deciding if he should carry a new coilover system from BC Racing. It looks like my humble GTI will be the testing car. The coilovers in question look very nice. All black with really solid feeling adjustable knobs for dampening.

Right now I'm regretting not being patient. I've got a MKV GTI and I love it to death, but the just announced pricing on the Jetta Sportwagen TDI means I could've got that for almost the same price! The Sportwagen has more room, decent power, and AWESOME gas mileage.

I've got a MKV GTI and I really love cars in general. I'm going to use this part of my blog to document my car's progress and hopefully post some how to articles about some of the modifications. Thanks to a partnership between my coding abilities and Raderwerks, it looks like I'll be getting some goodies soon!