(Updated 8-26-04 to repair photo links)
I installed an iPod dock in the ashtray of my '04 Passat wagon. I wanted an installation where I did not have to connect wires to the iPod; I could just select a playlist, start the iPod, set it in the cradle, and listen to music. I also wanted to be able to install this without removing the head unit or the console. I installed everything through the shifter boot hole and the hole under the armrest.
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Used in the installation
iPod dock (came with iPod)
Belkin power adapter (eBay)
20 ft audio cable, RCA plugs (Best Buys)
BlitzSafe CD changer to RCA plug adapter (Enfig.com)
Audio adapter - 1/8" plug to RCA plug adapter (junk box)
inline fuse holder, 1 amp fuse, shrink tubing, solder (junk box)
12V inline connector (hardware store)
I pulled the shifter boot and determined that if I ran the wires from the dock downwards I could avoid hitting the ashtray cover. I took the iPod dock apart. After removing the copper tape I was able to remove three screws and remove the metal weight. I then removed the three screws that held the audio and dock cable connectors. I gently bent the copper foil encased ribbon cable until the connectors faced toward the base of the dock. I used a Dremel tool to carve an opening in the dock base for the connectors. I replaced the metal weight and made a plastic spacer (from an old CD case) that was attached via the screws that used to attach the connector. The spacer holds the connector in place.
Unmodified Dock
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Disassembled Dock
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Modified Dock
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I did a test fit of the modified dock in the ashtray well. The cover was too large so I cut away material in the rear of the cover until it would fit. I also cut both the dock base and cover to clear the contour of the front side of the ashtray well. Once everything fit I painted the iPod dock black to match the car.
Test fit
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Modified dock cover
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Now for the job of cutting the ashtray to fit the cables. I put double stick foam tape on the dock connector. I placed the dock in the ashtray well, the foam tape transfered to the ashtray well and showed where I had to cut for the wires. I used the Dremel to cut a slot for the dock connector cable and a larger hole for a 1/8" audio plug. I then put modeling clay in the well and again put the dock in place. The clay gave me the shape of the spacers I would need. I cut two wooden spacers, one contoured to the ashtray well that went under the front portion of the dock and a smaller one for the rear of the dock. The dock was placed so the iPod just cleared the ashtray cover when the cover was open. After I was satisfied with the dock position I attached the smaller spacer to the ashtray and the larger one to the dock using silicone adhesive.
Hole in ashtray well
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The power cable was based on the cable described here:
http://www.mindspring.com/~pmbenn/iPod/cable.htm
I carefully stripped the red and black wires on the Belkin adapter, plugged them in to the car power plug, and checked voltage. I got 12.6 V with the car off, 13.8 V with the car on and about 10 V while cranking which convinced me that the Belkin adapter did not regulate the voltage to the iPod. I also checked the specification for PowerMac Firewire connectors,
http://developer.apple.com/document...rMacG5/3Input-Output/chapter_4_section_3.html
it allows up to 25 V on the Firewire power leads.
Convinced that hooking the iPod to the Passat 12V was OK I cut off the Belkin cable at the end opposite the iPod connector. I stripped the tiny black (ground) and red (+12V) wires. I soldered the fuse holder to the red wire. I soldered the power lead from the inline connector to the fuse holder. I cut a length of wire to connect the black from the Belkin cable to the ground lead from the inline connector. I used various sizes of shrink tube to both insulate and mechanically reinforce the connections. The length of the power cable reached from the iPod dock in the ash tray to the rear seat power connector in the rear of the console.
Power cable
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I removed the rear of the console to give access to the power connector leads. I used crimp connectors to attach the other end of the inline power connector to the VW wiring. Checked everything with a voltmeter, then ran the power cable along the right side of the console and fed the iPod connector through the slot below the ashtray.
Power cable installed
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I fed the audio adapter cable through the hole below the ashtray. The 20 ft audio cable ran from the shifter area of the console, forward in the console, under the dashboard just aft of the pedals, behind the cover by the drivers left foot, then under the plastic trim along the left side of the car to the CD changer area. I had about 2 ft. extra, which I coiled near the BlitzSafe. I connected the audio cable to the BlitzSafe and to the 1/8" to RCA adapter.
Audio connector
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I connected the iPod dock to both cables and confirmed that everything worked. I then used silicone adhesive to mount the iPod dock in the ashtray. After the adhesive cured I used adhesive backed pads and tie-wraps to hold all of the wires in place.
Final result
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I completed a 500 mile test of the installation last weekend. It works great!
I installed an iPod dock in the ashtray of my '04 Passat wagon. I wanted an installation where I did not have to connect wires to the iPod; I could just select a playlist, start the iPod, set it in the cradle, and listen to music. I also wanted to be able to install this without removing the head unit or the console. I installed everything through the shifter boot hole and the hole under the armrest.
Used in the installation
iPod dock (came with iPod)
Belkin power adapter (eBay)
20 ft audio cable, RCA plugs (Best Buys)
BlitzSafe CD changer to RCA plug adapter (Enfig.com)
Audio adapter - 1/8" plug to RCA plug adapter (junk box)
inline fuse holder, 1 amp fuse, shrink tubing, solder (junk box)
12V inline connector (hardware store)
I pulled the shifter boot and determined that if I ran the wires from the dock downwards I could avoid hitting the ashtray cover. I took the iPod dock apart. After removing the copper tape I was able to remove three screws and remove the metal weight. I then removed the three screws that held the audio and dock cable connectors. I gently bent the copper foil encased ribbon cable until the connectors faced toward the base of the dock. I used a Dremel tool to carve an opening in the dock base for the connectors. I replaced the metal weight and made a plastic spacer (from an old CD case) that was attached via the screws that used to attach the connector. The spacer holds the connector in place.
Unmodified Dock
Disassembled Dock
Modified Dock
I did a test fit of the modified dock in the ashtray well. The cover was too large so I cut away material in the rear of the cover until it would fit. I also cut both the dock base and cover to clear the contour of the front side of the ashtray well. Once everything fit I painted the iPod dock black to match the car.
Test fit
Modified dock cover
Now for the job of cutting the ashtray to fit the cables. I put double stick foam tape on the dock connector. I placed the dock in the ashtray well, the foam tape transfered to the ashtray well and showed where I had to cut for the wires. I used the Dremel to cut a slot for the dock connector cable and a larger hole for a 1/8" audio plug. I then put modeling clay in the well and again put the dock in place. The clay gave me the shape of the spacers I would need. I cut two wooden spacers, one contoured to the ashtray well that went under the front portion of the dock and a smaller one for the rear of the dock. The dock was placed so the iPod just cleared the ashtray cover when the cover was open. After I was satisfied with the dock position I attached the smaller spacer to the ashtray and the larger one to the dock using silicone adhesive.
Hole in ashtray well
The power cable was based on the cable described here:
http://www.mindspring.com/~pmbenn/iPod/cable.htm
I carefully stripped the red and black wires on the Belkin adapter, plugged them in to the car power plug, and checked voltage. I got 12.6 V with the car off, 13.8 V with the car on and about 10 V while cranking which convinced me that the Belkin adapter did not regulate the voltage to the iPod. I also checked the specification for PowerMac Firewire connectors,
http://developer.apple.com/document...rMacG5/3Input-Output/chapter_4_section_3.html
it allows up to 25 V on the Firewire power leads.
Convinced that hooking the iPod to the Passat 12V was OK I cut off the Belkin cable at the end opposite the iPod connector. I stripped the tiny black (ground) and red (+12V) wires. I soldered the fuse holder to the red wire. I soldered the power lead from the inline connector to the fuse holder. I cut a length of wire to connect the black from the Belkin cable to the ground lead from the inline connector. I used various sizes of shrink tube to both insulate and mechanically reinforce the connections. The length of the power cable reached from the iPod dock in the ash tray to the rear seat power connector in the rear of the console.
Power cable
I removed the rear of the console to give access to the power connector leads. I used crimp connectors to attach the other end of the inline power connector to the VW wiring. Checked everything with a voltmeter, then ran the power cable along the right side of the console and fed the iPod connector through the slot below the ashtray.
Power cable installed
I fed the audio adapter cable through the hole below the ashtray. The 20 ft audio cable ran from the shifter area of the console, forward in the console, under the dashboard just aft of the pedals, behind the cover by the drivers left foot, then under the plastic trim along the left side of the car to the CD changer area. I had about 2 ft. extra, which I coiled near the BlitzSafe. I connected the audio cable to the BlitzSafe and to the 1/8" to RCA adapter.
Audio connector
I connected the iPod dock to both cables and confirmed that everything worked. I then used silicone adhesive to mount the iPod dock in the ashtray. After the adhesive cured I used adhesive backed pads and tie-wraps to hold all of the wires in place.
Final result
I completed a 500 mile test of the installation last weekend. It works great!
