Replicating the late 02 model console panels
I have been experimenting and researching how BMW manufactured the console panels on our beloved 02s. This all started about six months ago, when I was faced with my 76 raggedy panels and interior renovation. I first tried to find replacements that were new or nearly new ones. That proved to be a dauntless task, as mine were actually in better condition than many of those that I was finding and or the prices were excessive. After giving up finding new replacements, I resorted to try to figure out and research how they were actually made by BMW. Then maybe I could try to reproduce me a set.
The biggest question I had, how the heck were the edges of the vinyl joined around the perimeter of the panels such that the ends look so crisp and straight and held up so well for so many years? If they were not glued, sewn, stapled, what kind of method or process allowed the manufacturer to produce such crisp robust console panels? In putting my old 02 units under the magnifying glass, I noticed that they came apart at the edges due to the inner particle board swelling and expanding more than the tight-fitting vinyl could stretch.
Over several months, I felt like I finished the internet, Lol. For hours at a time, I googled all I could lay my eyes on regarding vinyl joining/bonding techniques, such that the end product had the appearance and durability of the OEM panels. At the same time, I was experimenting with different types of vinyls. I was mostly experiencing separation failures as I applied controlled heating and pressure techniques and the final results were not impressive. This went on for many weeks, gradually changing the way that I applied heat to the edges and varied the pressure as well. At the same time, I was also trying different wood types and edge cuts and profiles that were as close to the OEM.
After months of research and experimenting, I was about to give up when I came across videos on vinyl floor bonding with heat. This gave me some ideas. I accepted the fact that I was not going to find out the BMW secret. However, I did, be it accidentally, discovered and resorted to the fact that I could weld the vinyl in a way that looked similar and stayed together in the same way as OEM! And guess what?, no staples, stitches or glue to hold it all together! So, yes, the solution was to weld the vinyl together at the edges, which in essence makes two vinyl pieces into one, and result in something close to OEM! Admittedly, the welding was the key part, but there was also a lot of figuring out of applying the right amount of stretch and not produce any wrinkles on any of the edges, while maintaining a uniform surface front and back.
Many days later, I was able to fabricate a set of panels where I made some aesthetic mistakes, but that I was happy with would work on my 02. They looked better than my old worn-out originals and were robust. It was then that I decided to fabricate additional units to see if I could improve upon, primarily aesthetically. So far, it worked out pretty good. Naturaly, as an engineer, I put together some questions that I asked myself that others may ask with respect to the over-all finished product to evaluate if the panels would even worthwhile.
- In appearance, are the panels exactly the same as OEM? - Yes and No. The front and edges probably yes, the back, not quite, as the OEM has a thin (~1/16") heat seam, while mine have about +1/8" of heat seam and slight bulging on the back resulting from the welding process.
- Will the vinyl come apart or separate at the edges from extreme heat or cold? - No, it will not separate or come apart at the edges, as the vinyl (marine grade) itself would have to melt to release the bond.
- What kind of material is used for the panel itself? - The panel is the same thickness as the OEM, additionally, from Wikipedia. Medium-density fibreboard (MDF) is an engineered wood product made by breaking down hardwood or softwood residuals into wood fibres, often in a defibrator,
- What happens if the adhesive between the MDF and vinyl fails? - Nothing would happen, as the vinyl is molded around the shape of the MDF and profile and welded together at all surrounding edges.
- Will the vinyl hold up in extreme hot or cold temperatures? - The vinyl is a re-inforced marine product that is incredibly durable and is designed for the outside environment, boats, recreational vehicles, including UV, salt, heat and cold and especially inside the car, it will not degrade with time, hot/cold conditions.
Shoot me any questions that you may have on my endeavor. I would also love to hear about your interior 02 projects and challenges!!
Jesse
- 6
- 1
22 Comments
Recommended Comments
Create an account or sign in to comment
You need to be a member in order to leave a comment
Create an account
Sign up for a new account in our community. It's easy!
Register a new accountSign in
Already have an account? Sign in here.
Sign In Now