Instrument Panel Cutout

[Sprockett]

The original owners of my '74 Glastron Sportster plastered on a piece of metal for an instrument panel, added one switch for lights and mounted a depth finder and called it good.

I'm going add a whole set of intstruments and switches to the panel, so I took measurements and did a CAD drawing of the dash and then cut them out on my CNC as templates. My idea is that I'll create the new panel using either carbon fiber or maybe polycarb and glue some really nice wood burl to it. Since I can cut things with the CNC I can get an exact fit for everything.

What I want to do is cutout all the current panel area in the boat, leaving some areas to mount the new panel too, this will allow me to mount the instruments and wire the entire dash on the workbench and then just take it out and bolt it in, and if I want to change it I can just unbolt it and make whatever changes I see fit.

Attached is the new test template (made of hardboard), the outline piece I was going to use to cutout the dash and a picture of the dash itself.

What I want to know is how do I cut out the dash material?, can I just use a little hand saw? or does a small router work better?

I've never cutout glass like this before so I'm looking for the best way to approach this so I don't screw up the boat........

Thanks

-Paul-

 

[Scaaty]

Re: Instrument Panel Cutout

Probably just drill some large (for the blade) corner and spacing/reference holes, and go at it from the inside with a jigsaw, or Sawzall.?

 

[ddrieck]

Re: Instrument Panel Cutout

You could use a small key-hole (fine tooth), rotozip, or a dremel tool. I would refrain from using a router as there usually big an combersome. Ant of the before mentioned tools are smaller and easier to get into the area your wanting to cut out. If you use the rotozip or dremet tool make sure use wear a good dust mask. You don't want to inhale any of the glass dust created.

 

[GiMLit]

Re: Instrument Panel Cutout

The original owners of my '74 Glastron Sportster plastered on a piece of metal for an instrument panel, added one switch for lights and mounted a depth finder and called it good.

I'm going add a whole set of intstruments and switches to the panel, so I took measurements and did a CAD drawing of the dash and then cut them out on my CNC as templates. My idea is that I'll create the new panel using either carbon fiber or maybe polycarb and glue some really nice wood burl to it. Since I can cut things with the CNC I can get an exact fit for everything.

What I want to do is cutout all the current panel area in the boat, leaving some areas to mount the new panel too, this will allow me to mount the instruments and wire the entire dash on the workbench and then just take it out and bolt it in, and if I want to change it I can just unbolt it and make whatever changes I see fit.

Attached is the new test template (made of hardboard), the outline piece I was going to use to cutout the dash and a picture of the dash itself.

What I want to know is how do I cut out the dash material?, can I just use a little hand saw? or does a small router work better?

I've never cutout glass like this before so I'm looking for the best way to approach this so I don't screw up the boat........

Thanks

-Paul-

well damn
I need to make a new dash plate and wish I had a CNC to do such a nice job!

 

[i386]

Re: Instrument Panel Cutout

Fiberglass is pretty hard on tools, but there are router bits that are made for trimming fiberglass. I think if you want your cutouts to looks as precise as your CNC job (very nice btw) you can rough out the holes then use one of those hardboard pieces as a template for your router. I think it will turn out nicely.

 

[Sprockett]

Re: Instrument Panel Cutout

Thanks for the info, I have various hand tools that will do the job then, I'll make a tracing with the template and then cut it out that way.

And GimLit... I do some custom work if you really want one, just PM me. I use the machine for building guitar parts and jigs, but when I do stuff like this on it I have more fun

I don't cut metal on it, it's strictly wood and plastic.....

-Paul-

 

[Mark42]

Re: Instrument Panel Cutout

A sabre saw will do a nice job. Either have a lot of cheap fine tooth blades, or use a grit covered ceramic cutting blade. Fiberglass will dull a regular toothed saw blade pronto.

 

[OhWellcraft]

Re: Instrument Panel Cutout

A sawzall would work well, I have cut alot of glass with one. Make sure however you use a fine blade and go slow, do as mentioned and drill 1" or so holes in the corners first. Then you can stick the blade in them and come at the corners from both ways. When you have three of the sides cut you may want to clamp the cut out piece somehow so it doesnt want to drop when you get close to the end of the fourth side. Sometimes it will want to drop out thus causing it to crack or fracture where you may not want it to. A 8" blade may be better so you can have more clearance with the tool and surrounding areas(side glass, steering wheel, windshield, etc) There is a blade between a wood rough in type and a true metal cutting type Ive always had the best luck with. Real nice work on the templates, having a removeable panel would be sweet when I redid mine I got a pretty kinked neck from crawling under the dash area for so long. Are you going to leave some length on all the wires or use some kind of connectors? to do all of your final tie ins? Keep at it you will get there I saw your busted post Ive been there ha ha it's hard to explain the need to want things done and done right but sometimes it seems you just have to compromise and deal for a while. Like when I used a boom box with a lighter cord attached instead of the killer stereo system I had all planned out oh well it came with time though.

 

[Sprockett]

Re: Instrument Panel Cutout

I'm using standard connectors and everything will be crimped and heat shrinked, I will be wiring those into a fuse block that will be clearly marked as well (everything gets a label).

My current plan is that there will be a small fuse block in the back by the battery, this will handle electrical items needed back there. Then wires like the fuel sender will wire up to the front fuse block, where they will then be fused and plugged into the panel.

What I'm struggling with now is what material to use to epoxy the burl onto, it needs to be strong and take epoxy. I don't think wood is the answer, some type of fiberglass matt or something along those lines. What I will do is flood epoxy the burl on, let it cure and sand it smooth and then polish it. believe it or not epoxy is a great finish for wood

-Paul-

 

[OhWellcraft]

Re: Instrument Panel Cutout

Is thickness an issue? if not I would think some good 1/2" ply would work well then saturate it with some thinned epoxy to seal it up. Then when you do the burl there will be an epoxy base for it to adhere to better. Are you going to wrap the burl over the edges? you would almost have to if you use something a bit thicker. The only reason I asked about the wire length is if you ever had to remove the panel you would need a loop or two so you could pull it off and not have to remove shrink wrap from connectors, due to short wires also when doing the initial wireing it would make it much easier if you had a bit of extra length. If the ply idea is no good I'm sure others will come in with some more ideas. I wonder if you could layup some cloth and epoxy on the hardboard piece you already have, that is such a nice piece seems ashame to not use it.

 

[oops!]

Re: Instrument Panel Cutout

I took measurements and did a CAD drawing of the dash and then cut them out on my CNC as templates. Since I can cut things with the CNC I can get an exact fit for everything.

freekin cheater...

......im making a whole new dash and ive got to hand sculpt it from foam and glass the foam. !

dont want to go against the grain here...but a sawsall might damage the gellcoat if not done correctly.....

im personally a big fan of a rotary saw for this type of cut....if you choose the sawsall ....use tape over the cut line so you dont damage the glass.

cheers
oops

 

[Sprockett]

Re: Instrument Panel Cutout

freekin cheater...

......im making a whole new dash and ive got to hand sculpt it from foam and glass the foam. !

dont want to go against the grain here...but a sawsall might damage the gellcoat if not done correctly.....

im personally a big fan of a rotary saw for this type of cut....if you choose the sawsall ....use tape over the cut line so you dont damage the glass.

cheers
oops

Hahahahha... SMOKE IF YOU GOT EM!!!!

I use the CNC for other things, but stuff like this is just fun.

I was thinking of using the famed Roto-Zip, it actually comes in handy every now and then .

-Paul-

 

[Sprockett]

Re: Instrument Panel Cutout

Is thickness an issue? if not I would think some good 1/2" ply would work well then saturate it with some thinned epoxy to seal it up. Then when you do the burl there will be an epoxy base for it to adhere to better. Are you going to wrap the burl over the edges? you would almost have to if you use something a bit thicker. The only reason I asked about the wire length is if you ever had to remove the panel you would need a loop or two so you could pull it off and not have to remove shrink wrap from connectors, due to short wires also when doing the initial wireing it would make it much easier if you had a bit of extra length. If the ply idea is no good I'm sure others will come in with some more ideas. I wonder if you could layup some cloth and epoxy on the hardboard piece you already have, that is such a nice piece seems ashame to not use it.

It's kind of an issue, I want something under .25" if possible, or your right I'll have to wrap the edges and I don't want to monkey with that, the piece I have it just pressboard (they call it hardboard) and it's not very sturdy. I could soak it with resin and add some matt and then make a sandwitch that way, I'll have to play with that. I have a vacuum jig I built some time ago thats perfect for making flat layups, maybe I'll try that...

Thanks for the idea

 

[littlebookworm]

Re: Instrument Panel Cutout

I've refurbished two boats so far and found the ziptool fantastic for cutting any kind of panel. Place some blue masking tape on the edge to protect the gelcoat and to give yourself something to draw lines on. Take off the steering wheel first. It'll only get in your way. Definitely wear a respirator, goggles, and ear protection. A disposable painter's cap also comes in handy. You can get all that stuff at Home Depot or Lowes. A long-sleeve shirt helps to protect your skin from fiberglass dust. Good luck. Hy

 

[Grits]

Re: Instrument Panel Cutout

Sprockett

I am with 386. You certainly appear to know how to use tools and understand precision. Using a router with a template would give you the best results. For a one shot deal, a any carbide bit would work fine. You may even use an end mill. I doubt I have to tell you this, but if you use HSS, watch the heat.

You can also cut the fiberglass with a jigsaw. In my opinion, a jigsaw would be more accurate than a sawzall (sp) but either would work fine.

Great work. I just thought I was cheating when I used my Bridgeport.

Keep us informed.

Grits