I had a couple requests to post this as a separate thread from "Matt's Graphic Overlay Projects" with more detail so here you go. This is the illuminated ashtray audio/iPhone/USB panel that now pairs with my new Parrot stereo. The process was pretty simple once I figured out a plan - just took time. I ordered an NOS ashtray from DMCMW, took it apart, and came up with the design to best compliment the car. The ashtray "bin" actually has indentations in the part you normally don't see (so I flipped the opening around so the cigarette snuffer is covered) where a thin, but very sturdy sheet of Lexan plastic rests perfectly when cut exact to fit. I then ordered a panel mount 1/8 inch audio jack and a panel mount double USB jack (had to do some tampering so it could pop through the Lexan. I then designed the graphic overlay and used that as a template to cut the Lexan to firmly hold the USB and audio jack mounts. I had to cut a section of the bottom of the ashtray in order for the USB mount to fit inside. I then took everything apart again and started to permanently assemble everything. I started with some super bright LED ribbon and placed it directly under the sections I wanted to illuminate - glueing it down to the bottom of the ashtray. Next I used "Steel Stick" to mount the Lexan panel followed by the USB mount using the putty as well. Then came the graphic overlay (a whole project in itself) affixed to the Lexan panel with a light spray of glue. Next came the 1/8 jack that popped into place. As you can see from the pictures, I used more Steel Putty to enclose and stabilize all of the wires (everything was soldered inside for long life) and mounts. To make it so I can take the unit in and out easily, all wires use snap connectors I got from Radio Shack. I used a few resistors to get the LEDs to the light level I wanted and then hooked the power into the shifter marker light. I snapped the top of the ashtray back on and voila! When shut, it appears stock. Works perfectly and should be there to stand abuse for the next 20 years.
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