Sunday, August 2, 2015

Control Panel and JLD404 Installation into the Center Console



Picture DSC04165 of the center console after removal of the Multi-Information Display Module and removal of the console from the car.  The Storing Partition Insert is still in place.





Picture DSC04166 front close up view of the Storing Partition Insert which includes the lighter and seat heating controls.



Picture DSC04159 of the BMW center console after removal from the 325i.  BMW calls these parts the Storing Partition (bottom and dark tan color) and the Storing Partition Cover (top section of black trim).



Picture DSC04112 showing the flexible rubber mat (left) after it was removed from the base of the plastic part (right).  Pushing the four tabs on the front underside of the opening (both backward and up) allows the tabs to snap free.  BMW calls the complete part the  Storing Partition Insert.



Picture DSC04114 showing the part before removing the rear storage section (left) and after the plastic had been cut away (right).



Picture DSC04115 showing an oblique view of the Storage Partition Insert after removal of the rear plastic.



Picture DSC04145 showing the three inserts (BMW calls them a Cover)  removed from the base.  It was hoped to install a switch in each insert, but the inserts were too narrow, so a black anodized aluminum plate was prepared that covered all three openings at the same time.



Picture DSC04155 showing the 0.125" thick black anodized Aluminum plate (McMaster 7083T21) after it was cut down to 3" x 1.75".  Four mounting holes to accept M5 .8 x 20 bolts are located 0.250 inches from top (bottom) and the sides (left or right).  The plate was then drilled (12 mm) to receive three illuminated SPST toggle switches (20 A, 12 VDC) that will control:  (1) activation of the pack relays (blue); supply +12 volts to energize the Soliton 1 (green); and supply +12 volts to the JLD-404 Amp Hour Meter (red).  Other functions may later share the use of these switches.



Picture DSC04154 of the bottom side showing the temporary nuts that secure the Aluminum plate to the BMW plastic part.  An Aluminum strip will later be added as a backing plate in lieu of using separate washers with each M5 .8 x 20 mm bolt.


Picture DSC04170   of the black anodized plate that was cut to cover the recessed opening of the Storage Partition Insert.  The overall plate was 2.6875" x 7.4375" x 0.125" and the opening for the JLD-404 meter is 1.6875" x 3.625".



Picture DSC04169 of the mounting plate with the JLD-404 installed.  Four mounting holes were next drilled, each 0.50" from the top(bottom) and side edges.




Picture DSC04181 showing the 3/4" x 3/4" x 1/16" right angle Aluminum pieces ( 2.75" long) that were used as backing plates along with machine screw nuts to secure the plate holding the JLD-404 to the Storage Partition.



Picture DSC04178 of the mounted JLD-404 in the mounting plate, secured to the Storage Partition Insert, and installed in the center console.  Initially #6-32 x 1.5" machine screws with fiber washers were utilized as they were on hand, but they will eventually be replaced with black screws to improve overall cosmetics.






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