What Material for Dash Panel??

[anon1]

Hello,

After one unusually hard landing the panel that holds the switches in the dash has broken.

The dash has the typical wood backing and some kind of vinyl like main piece. The switches are set into a seperate plastic panel that is then screwed to the entire dash assembly. The yellow outlined areas in the picture below.

The plastic pieces broke at each corner where it is screwed to the dash.

Any advice on a replacement piece of plastic that is less likely to crack and break?

I don't suppose that someone makes these parts for 20yr old boats?

Thanks.

 

[NSBCraig]

Re: What Material for Dash Panel??

What kind of Baja do you have?

Did you consider making them out of some aluminum? Might solve the stress issue.

 

[92excel]

Re: What Material for Dash Panel??

could be cool if you didnt match it.. like come back with stainless steel, chrome, graphite or even wood grain.. whatever you want!

 

[anon1]

Re: What Material for Dash Panel??

What kind of Baja do you have?

Did you consider making them out of some aluminum? Might solve the stress issue.

1989 Baja Force 216 w/ 350Mag & Alpha1

Any idea how thick you can get sheet aluminum? I think that would be a good idea to use aluminum and then paint it black if I can get it thicker than a beer can and not have to buy a big sheet of it.

[add] I found aluminum at metalsdepot.com, (2)1'x1'x1/8"thick for $40. Still looking for thicker, maybe 1/4".

 

[J. Mark]

Re: What Material for Dash Panel??

1/8th aluminum is plenty thick. If you want it thicker to duplicate what was in there in plastic, just shim it out.

Anodized aluminum would look sharp too.

 

[ondarvr]

Re: What Material for Dash Panel??

Check the yellow pages under plastics, you'll find a few places that sell sheets in many different patterns, colors, textures and thicknesses, you should be able to find something you like.

 

[drewpster]

Re: What Material for Dash Panel??

I think you find that 1/8 is plenty thick enough for what you wan to do. I have built a couple of panels using aluminum that is thinner than that. Also a thinner gauge will allow you to cut the openings you will need much easier. I used a drill and a jigsaw to make the openings in mine. I also have used bi-metal hole saws for the same purpose. Any thicker and it will be a pain. I cannot remember the thickness that I used but it is much thinner than 1/8" and much less expensive. Check a local metal supplier, I think $40 is a bit steep. You may also have a local powder coater. I had this panel powder coated and it is plenty stiff.

 

[NSBCraig]

Re: What Material for Dash Panel??

Hey that's a cool idea you could powder coat it or even cover it with vinyl (I'm thinking engine turned).

I think 1/8" should be fine.

Wonder what it would cost just to order them made and finished?

 

[contractorguy]

Re: What Material for Dash Panel??

I've seen small pieces of 1/8" aluminum treadplate at homedepot...

How about little triangular 'gussets' that just lay over the broken corners?

 

[anon1]

Re: What Material for Dash Panel??

Thanks everyone for the input. Please keep the ideas coming.

- 1/8" seems to be thick enough

- black anodized would be ideal

- regarding plastic: it's not about finding something that I like, it's finding something that will not break again. Still ruling out thin plastics.

- I've ruled out any reflective surface due to the blinding effect it might have. No engine turning, chrome, raw stainless, diamond tread, etc.

- I know people with cnc and non-cnc machining equipment. Talking to them about cutting it for me.

- Thinking about the corner gusset route. First impressions are that the "old" plastic piece would likely break again at the point where the gussets attach to it. (Just break off a bigger corner than the first time.)

- 1/8" AL weighs about 1.8lb per sq.ft. = 1'x1' would weigh 1.8lb, then subtract for all of the cut-out areas, say 1/4 of the panel = 1.35lbs each. I'll have to look at the dash construction again and consider this weight.

- Can stainless be cut and finished easily? No shiny, blinding pieces allowed.

So, I need to:

1. find some aluminum sheet and "test" its flexibility at 1/8" thick and thinner. Going for low flex at the thinnest 1'x1' piece possible.

2. find black anodized aluminum that is sold in small pieces. So far I've only found whole sheets for sale.

3. Talk to my machinist friends about making all of the cut-outs and possibly engraving the switch labels through the anodizing. See which would be best for them to work with, aluminum or stainless.

4. Get price for powder coat of stainless.

Thanks and Merry Christmas.

 

[NSBCraig]

Re: What Material for Dash Panel??

You wouldn't want to spend the extra dough for stainless if your gonna powdercoat it.

I did powdercoating for 4 years and can't remember one part I did that was stainless.

Just use Aluminum.

I'm also not sure about a buying a piece anodized and then cutting it, for two reasons- one scratching it up two it's not protected on the fresh edges.

Have you tried companies that make panels?

I can't remember any names right now (have cold and well medicated) but we used to deal with a couple that you could just spec it out and get it finished and even engraved.

**beautiful day for boating and I'm stuck in side with a cold, unbelievable**

 

[drewpster]

Re: What Material for Dash Panel??

I think the ideal thickness for the size panels you are making should be about the thickness of a street sign.
Sheet aluminum is common. You should be able find it locally. It is easily cut with common tools. If you have a drill and a Jig saw you can make all the openings I can see in your pic. After cutting, sand the surface to smooth out all the burrs. You can prime and paint but powder coating is more durable. I am sure anodized panels can be found, but its going to cost you. I think I spent maybe $30.00 (from memory) for a half sheet of aluminum. (4x4) After making all the openings I gave the panel and all the related parts to the powder coater. He had them back the next day. ($20.00) Fifty bucks may seem a bit much for my panel. I do have what is left over from my cut sheet. I was mentioned in earlier posts, I am sure you can find cut pieces for next to nothing. You might look for a local fab shop. I am sure they would have plenty of scrap. If you look needy enough, they may just give you what you need. Kinda like this please?