Replacing a Dash Mesh with B&O

[IT]

After replacing my B&O center dash speaker in this thread here: http://forum.a8parts.co.uk/showthread.php?t=6402 I didnt want to put the original mesh back as it was discoloured and quite awful:



My second problem is that picking up a spare mesh is not that easy. The B&O one is significantly smaller than the regular A8 one, so finding a breaker with one, and in good condition, and carefully removed was not going to be easy:



Interestingly though, the B&O one looks to be literally sawn off from a regular mesh, rather than specially made, so a quick pit stop at a8parts for a regular one which they had in stock and the job could commence



Using an old duvet to protect the mesh I attemped the line them up and draw pencil lines to govern where the cut was going to go:



But with such an irregular profile, it was tricky to really get the measure, so intead decided to use the hexagonal shapes on the underside as guidance, and using the old B&O mesh as a template just lined up the hack saw cutting the hexagons exactly where they were on the old one.



A few strokes and dusted it off to sanity check we're on the right track:



and we plough on gently, and eventually we're through:



and for quality control, here is the fresh offcut, offered up to the old B&O mesh and I think you'll agree its a mighty close fit.. I then dusted off the edges by hand, pressing any loose bits of mesh back down to create a flush edge. I avoided filing as it would probably make more mess than it tidied.



So, repeat on the other side obviously..... and voila



So, offer it back into place on the dashboard, sliding it in first to meet the windscreen then pushing down the edge flush with the dash





And pop the B&O covers back on - Note the covers do overlap the mesh slightly, so the precision with which the mesh is cut is maybe not vital, it seems the speaker cover was designed to cover up the cut basically...



Looking so much better already:



And the tweeter cover at the other side:



And the finished result, which I'm really pleased with:

[snapdragon]

Good job, but what the hell happened to the old one?

[PsYcHe]

Looks like the old one may have been hit with a slightly too aggressive cleaner.

[Dezzy]

Give it a quick rub over with something like oven cleaner, wash off and re-piant?

[limoncello]

great write up

[IT]

Originally Posted by Dezzy

Give it a quick rub over with something like oven cleaner, wash off and re-piant?

Considered that, but getting a paint to match seemed harder work than just cutting down another one. If the paint was even slightly the wrong shade or degree of shine it would simply annoy me as non standard ...

[IT]

Originally Posted by snapdragon

Good job, but what the hell happened to the old one?

I dont know. I've pondered this quite a bit. Most of the marks you see are actually small patches of rust coming through. There were 1 or 2 very small similar marks on another mesh a looked at, so maybe they are just incredibly sensitive to getting scratched, and then moisture locks in.... Dunno really. Very pleased it looks perfect now though

[David's8]

Some domestic glass cleaners have ascetic acid (vinegar - an old wives trick for cleaning windows and leaving them smear free) in them. The pattern of corrosion on your mesh looks like could have come from spray??

[snapdragon]

Yes, I think you may be right. I will be careful about cleaning the windscreen now I know this part is made from 'monkey metal'.

[Oli18]

Great write-up Ian. Noticed you have done a few recently...worth adding to the sticky threads how-to list?

Oli