Brief Description: Pilot Head Rest & Rear LCD Reduex - Part 2
The new plastic on the replacement shells was a lot easier to cut and trim and file. The holes for the LCD and Cam came out perfect. The downside of the slightly larger shell size was that my headrest mount didn't quite fit any longer and was about 1/4" short on each side. Its kind of kludgey, but I added a screw in reverse into the original rivnut, screwed on a 1/4" threaded spacer, then used a standard 1/4" long machine screw on the outside to attached the plastic to the head rest. Worked out great. The other thing that worked out nicely because of the new larger shell size was that the four screws that attached the rear shell to the inside shell now sandwich *both* shells to the 1" standoffs. On the original shells, I had to over drill the inside shell which meant that it wasn't being held by the four rear screws. Much stronger arrangement now.
Finally, I added two new pieces of .032" sheet to the top and bottom of the head rest under support. This *really* strengthened the whole head rest assembly and made it far more rigid.
For today's work I pulled all of the LCD electronics out of the case. This made working with the installation a whole lot less stressful not having to worry that I might scratch the LCD screen. I'm thinking that I might just leave the electronics out for now and just send the whole assembly to the upholstery shop. That way they can apply upholstery to the headrest and get a good idea of how to work around the LCD and Cam installations.
