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Old 09-21-2015, 03:45 PM   #1
Orbitcorbett
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Janus-Design double din install kit received!

I received my package from Janus Design today. The kit ran me about $114 US at the current exchange rate, and the photos posted show all that arrived. Note: they merely wrapped the metal pieces in thin packing paper and it was all rattling around in this oversized box - bubble wrap would have been a better choice for shipping material, but at least it got here intact.

The metal brackets are a sturdy steel that appears to be laser cut and tack-welded construction. The bends are very nicely done, and everything appears very sturdy.

I am getting ready to modify my AC duct according to the instructions booklet (a 23 page color PDF document) and using their provided cut template. I will post updates as I complete this install.

I will install my Pioneer AVH-4100NEX head unit once the Janus kit is installed.

Stay tuned!

Steve
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Old 09-21-2015, 09:29 PM   #2
toy4to
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Please note that their template in the pdf file won't be very accurate. The template was to be printed on A4-sized paper, not 8.5x11. So when you print it out, the proportions are off. Just keep that in mind, you're gonna have to modify the cutout a little bit to compensate.

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Old 09-21-2015, 09:35 PM   #3
Orbitcorbett
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Template

Yes, i've read that. I'll check it in Photoshop and be sure it's scaled right for the paper when I print it.
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Old 10-13-2015, 09:11 AM   #4
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UPDATE: Installation has begun

So, I finally got some free time and started my installation of the Janus Designs kit, in preparation for the install of my Pioneer double din.

I decided to start with the part I had been dreading, the part that seemed the hardest, which was installing the Janus pieces and modifying the heater core housing below the radio. Surprisingly, with a dremel, a Phillips screwdriver, and some ordinary minor hand tools, as well as some aluminum adhesive tape, I knocked it all out in under 3 hours.

The main purpose of the Janus design pieces is to a) provide you with a nice metal bracket for mounting your head unit, and b), provide you with a nicely made metal box and instructions to cut and modify the heater duct to obtain clearance for your new head unit.

Of course, to do this install, the AC control module moves below the radio into the spot where your sunglasses cubby resides. That provides you with the room needed for the new head unit.

I started by removing the lower cig lighter/cubby bracket and framework, removing the shifter knob and panel beneath it, and then moved on to pull out the radio and AC module.

I won't go into every detail here, because if you get this kit and do the install, you'll sort many of the details out for yourself. I just want to post some pics I shot and illustrate for you what I discovered, and how I resolved certain aspects, which might be of help to others who want to do the same thing. Believe me, this is not as bad or troublesome as you might think, if you are handy with tools and resourceful in your methods.

The first photo shows what it looks like with the hardware removed, and with the front panel of the AC box removed. This panel is held in place with small metal spring clips which pop off easily, exposing the heater core itself. It's nice to know that the heater core can be swapped out without taking the whole dash apart.
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Old 10-13-2015, 09:32 AM   #5
Orbitcorbett
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This shows the upper surface of the heater box after having been cut with a dremel, using the template Janus provided.

An important note about the Janus template is that it is scaled to print properly on A4 size paper, which is a European size that we don't have the in States. So, I opened their PDF in Photoshop, and rescaled the outer dimensions so that it is the correct size and scale when printed on a letter size 8.5 x 11 sheet. If anyone wants me to send them a properly scaled for the US version, just message me. I can email it to you.

With a dremel and a fresh cutoff wheel (the fiberous kind), I made these cuts in about a minute. It was not as difficult as I had thought getting the Dremel into the area and making the cuts. It was like butter.
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Old 10-13-2015, 09:51 AM   #6
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This shot shows what the front panel of the heater box looks like after you cut it per the template. You'll notice the notch on the lower right. This is to clear the heater temp sensor that is inserted into that area after you get the new metal box in place.
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Old 10-13-2015, 09:56 AM   #7
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This shot shows the front panel back in place after both cuts are made. The metal Janus box fits into this area after you modify the yellowish heater flap control rod, shown hanging loose above the core. This control rod has to be cut near the end with a dremel, and a metal bracket from the Janus kit is installed, giving it an offset to clear the Janus box while still moving both flaps to allow the heat to escape and heat the interior.
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Old 10-13-2015, 10:04 AM   #8
Orbitcorbett
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Another part of this install is that the right heater flap has to be removed and you have to cut half of the flap away with a dremel. This is necessary because the Janus box's right side is so close to the flap, that when the flap opens in heater mode, it would kick left and hit the side of the box, and not allow full flap movement.

The Janus instructions call for taking the cut-off piece of flap and using super glue to glue it to the inside of the right duct where it normally mates. However, I did not go this route, as I felt the super glue would not be sufficient to hold it for the long term. It seemed like a sort of cheesy method to block this part of the heater flap area.

In this photo, you can see what I did instead. I used very thin aluminum (the kind used for roof flashing), which is easy to cut with scissors or cutters, and can be easily bent and formed. I formed a piece of aluminum with flanges, and blocked off the open area of the duct as shown. If you don't block this opening off, you'll get heat out of the heater on the passenger side all the time, which you certainly won't want in the summer!

I used the aluminum ducting tape (not duct tape) as shown to seal up and hold the piece in place, along with automotive grade double sided tape. I cleaned the plastic surfaces well with alcohol first for good adhesion.
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Old 10-13-2015, 10:08 AM   #9
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In this last photo, you can see the completed box installation. The Janus instructions show using a special right-angle drill to vertically drill holes for the upper flange. I do not have one of these drills, so I did not install screws in that position. Rather, I drilled a few extra holes in the front of the flange and installed short screws to hold the metal box in place. Janus also supplies a length of soft foam insulation tape to seal all around the edges. I installed this tape, and then used the aluminum tape to cover all the corners and edges. Now, I am ready to install the stereo with the clearance this box provides.
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Old 10-21-2015, 06:40 AM   #10
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Nice job! The janus kit makes everything go so easily.
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Old 10-21-2015, 09:41 PM   #11
Orbitcorbett
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Yes, the Janus kit is nice, but pricey. If you are good at fabricating sheet metal and are willing to follow the Janus instructions, you could create the same parts yourself in one form or another. In my case, I went ahead and spent the money, and within 2 weeks, it arrived from Germany.
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Old 11-07-2015, 07:41 PM   #12
Robd360
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two questions:
1). what kind of car did you put in your Pioneer 4100nex?
2). where did you get the Janus kit? i cant find this on the net and there is no link anywhere

I have a 2002 BMW 325i 4-door. i got this radio installed yesterday by a radio installer. everything works fine but the radio totally sticks out i am looking for a solution to make it flush. hopefully its a matter of cutting more?? maybe the Janus Kit will help?? please help! as it stands, its a beautiful radio but it does not look good sticking out like that at all
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Old 11-07-2015, 08:11 PM   #13
Orbitcorbett
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http://www.janus-design.net/

They have multiple language versions of the website you can select from. The kit apparently comes from Austria or Germany.

The 4100NEX was installed in the BMW that is the subject of this post. Photos are attached here, showing how it should appear. It's night here, so best I can do in the available lighting.

You cannot install a standard double din in an E46 without creating the notched area in the top of the heater box, as the dimensions will now allow for it. That is why the Janus kit is so nice, because they have done all the "figuring out" for you, and it works well. You still have a bit of a tight fit with the wires and connectors behind the radio, but at least it does work.
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Old 11-07-2015, 08:30 PM   #14
Robd360
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Wow! Looks nice and flush. What year BMW do you have? 325i?? 2 or 4 door?
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Old 11-07-2015, 08:51 PM   #15
Orbitcorbett
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Thanks, mine is a 2000 328i 4 door.
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Old 11-10-2015, 09:20 PM   #16
Robd360
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Quote:
Originally Posted by Orbitcorbett View Post
Thanks, mine is a 2000 328i 4 door.
cool. im going to get the Janus kit and take the plunge. Hopefully the radio installer did not cut much down there and its salvageable. can you please send me the PDF scaled copy you made? thanks!
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Old 11-11-2015, 08:03 PM   #17
Orbitcorbett
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Janus-Design E46 template

Here is a JPEG of the template, so you don't have to deal with PDF as a file format. The sizing issue happens because the Germans who created the template forgot that here in the US, we don't use A4 size paper, and the drawing is sized for an A4. When you try and print it in the US on a standard letter size sheet, the scaling feature in the print driver can screw up the printed size.

I've sized the outer dimensions of one for 8" high and 10.5" wide, so if you print it at 100% scaling, it will come out fine on a regular 8 1/2" x 11" page. Just don't tell it to "fit to paper" or anything like that in the print settings, as that too will throw off the size a tad.

Let me know if you have any questions. Good luck.
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Old 11-11-2015, 09:23 PM   #18
Robd360
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did you also get the bezel from Janus as well? since we got the same exact radio, which bezel, from where did you use? if you got it from Janus, did you select the individual bezel, what dimensions?
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Old 11-11-2015, 09:26 PM   #19
Orbitcorbett
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No, I did not get the bezel from Janus-Designs. I went on eBay and found a suitable bezel and installation kit which also included the wiring harness plug. It was only around 10 to $15.
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Old 11-11-2015, 09:26 PM   #20
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The installation kit also included a small antenna adapter plug which is required.
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