Being a good 6.0 owner, I monitor. I run a CTS that is expanded to monitor fuel pressure and EGT. Anyway, I couldn't find a mounting solution that I liked. I liked the Edge supplied mount stuck low on the glass about center of the dash, but I don't like cables being visible. I don't like them stuck on the end of the dash because, well, they look like they are just stuck on the end of the dash. I ended up running mine stuck down in the corner of the windshield but I still wanted something different.
I thought having it up beside the rear view mirror would be nice. I had put off doing this until a buddy bought himself a 6.0 and was asking about CTS mounts. John, thanks for pushing me into gear on this.
This is a simple fabrication project and cheap enough that if you screw it up you can justify starting over. I've got right around $13 in this not counting paint, glue, tools etc. I started at Home Depot, picking up a 2X36X1/8 inch flat piece of aluminum and a pack of suction cups.
I then took a piece of card stock to use as a template. It has been folded around so many times that it is hard to tell what it is but I was using this to mock up angles rather than bending metal. I cut it 2 inches wide so I could see exactly what the metal would look like.
The closest thing to a high tech tool that I used was a belt sander mounted on a bench grinder. Honestly, the aluminum works easily enough that a sanding block with some 60 grit would work. Outside of that, I used a vice and a mallet to bend it, a hack saw to cut it and a few drill bits and one hole saw.
I started with the main piece which has two bends to it. I had hoped that it would work out to where I would have a single piece but no dice. I was afraid of vibration and ultimately the sunvisor clip getting loose, that is where the suction cup came it, a little added support for the other end of the "lever". The second piece has a single bend to it and it's only function is to hold the suction cup.
The only scary part was destroying the factory mount. I haven't checked but I'm sure they are readily available from Edge.
Take the "socket" and clean the cut off side up. It's a little gnarly but the ugly side gets pointed up and will never be seen.
You then need to trim the "nut" from this.....
A 1 1/8 inch hole saw make clearance for the sunvisor clip to mount.
I used a rivet to hold the two pieces together. Add a properly placed hole for the suction cup and another one for the CTS adjustment, and we're ready to see if this works or if I'm buying a mount from Edge.
I ran it like that for a week or so to see if any problems popped up. I only experienced one minor malfunction and worked that out in the final finish.
I popped the rivet out to seperate my pieces. My malfunction was in the adjustment, you really had to crank down on the nut to get it tight enough not to move and in doing so, the whole plastic deal would try to twist. I added a roll pin to prevent any rotation and in doing so fixed the "too tight" nut condition. Adjustment is easy breezy now.
On to finish......
If you so desired, this could very easily be polished to a chrome like finish, or painted your truck color, or powder coated, or, or, or.....
I tried for a factory look. I'm not 100% happy but I'll run it for now. It's just paint and glue so on a "I'm bored" weekend it can be changed. I wanted black to disappear into the tint and the Insight. I didn't like how the aluminum stood out against the headliner and black would do the same. So, I painted the mount in Dupli-Color Universal Black Metallic that I had left over from my home made Harley lights. In retrospect, where it is, the metallic disappears and has too much shine for my taste. I think low gloss black engine paint would have been a better choice for my taste. But it does look pretty awesome out in the sun. And check out the manly flower pots in the background!
To cure the contrast against the headliner, I went to Jo-Ann Fabrics and begged a chubby girl for a sample of tan headliner. She must have liked me because I got a big enough sample to build a handful of these. My wife still wants to know WTH happened at Jo-Ann to get a "sample" that big..........
I rolled and glued an edge. Then I glued the headliner to the mount up to the point where my second piece was attached, glued the front(?) edge over and cut a hole for the visor clip. Here she is.......
The color is off and that bugs the crap out of me. I will say that it looks closer in person than it does in pictures.
Details left out is the routing of the cables. My EAS cable was plenty long but the CTS cable was about 6 inches or so too short. My solution was to remove the DLC from the dash frame and gently pull to the left and they just do reach. Is it right? No. Does it work? Like a charm. You can't see it unless you look under the dash and it doesn't vibrate loose. The cables are run under the front edge of the headliner and down the A-pillar under the trim.
Like I said, this is an easy project. If anyone is interested, give it a shot.
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