I have found myself the lucky winner of the task of replacing the ancient video screen, radio controls & tape drive part of the “navigation & entertainment system” in a 1997 E38 BMW. I’ve so far done all the wiring to haul the head unit connections to the front of the car from the trunk and located a Sony double DIN head unit that will fit in the hole. I’ve done the CAD and have cut out some test brackets (which will be milled from a big block of plastic I have) to adapt the Sony to the ridiculously over-complicated die cast aluminium housing that the old video unit and tape deck lived in to mount it all in the Dash.
My next issue is to cut a suitable bezel to go around the new head unit and clean up the facia. I’ve considered trying to cut the die cast aluminium and walnut veneer bezel from the old unit but it just looks wrong with the Sony screen in it and I’m thinking a matt or silk black finish is likely to be cleaner overall. We plan to occupy the gap on the left with an iPhone holder for the attached Apple Car Play replacing the ancient navigation system.
So, any suggestions on a plastic that will machine well into these complex shapes and maintain dimensional stability and finish as it gets cooked and frozen in the interior of a vehicle pls?