reb78 Posted January 25, 2014 Share Posted January 25, 2014 Some time ago I built this out of mdf and covered if with black carpet tile: Shape wise it was fine, but the carpet gave it a 70s tacky look! Having lived with it for a while I decided to make a new face for it. Started with a frame for the top: Then plates to cover the top and hold the gauges: Painted black and mounted and this was the result: The bottom section where the radio is is currently just a thin metal plate folded over the wooden frame, but I'll replace this in a similar style to the top. The very bottom is free at the moment for more switches, an egt gauge and a second fuel gauge when I get round to buying/fitting the associated bits. Quote Link to comment Share on other sites More sharing options...
mmgemini Posted January 25, 2014 Share Posted January 25, 2014 Nice That is too clean for a Defender interior Quote Link to comment Share on other sites More sharing options...
studmuffin Posted January 25, 2014 Share Posted January 25, 2014 That's a neat bit of work Rich. Looks good. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted January 25, 2014 Share Posted January 25, 2014 Good work Rich. Quote Link to comment Share on other sites More sharing options...
benny777 Posted January 25, 2014 Share Posted January 25, 2014 nice one job well done Quote Link to comment Share on other sites More sharing options...
Snagger Posted January 26, 2014 Share Posted January 26, 2014 That's very tidy, but for what you have fitted, why did you not stick with the gauges and clock in the lower dash with the stereo in the standard mount? I presume you plan to put a lot more in, given the size of the console, so what are you going to fit? Quote Link to comment Share on other sites More sharing options...
reb78 Posted January 26, 2014 Author Share Posted January 26, 2014 Thanks chaps. It was just something to play about with really and give me a bit of practice with the welder and plasma cutter. It wasn't a good use of time really, as it took me days of fiddling to make it! I just kept looking at the raptor dash and it didn't appeal. If anyone can recommend a hole saw that will cut 52mm holes in metal and work with my pillar drill, that would be helpful. As it was, I had to cut a wooden template at 60mm diameter and then run the plasma cutter round the inside. The actual diameter of the holes in the metal sheet ended up at about 55mm, so the gauges were difficult to get tight and central in there! Snagger, I plan to add a second fuel tank and it's gauge and an egt gauge, so these will get added to the bottom section. Eventually, I will fit a series seat box in the back and then add a second battery and aux fuse box there. After that I'll add a few other electrical items - heated screen, lights on the side of the vehicle (a bit like Mike has for camping), and these will need switches that will go in the bottom section that is currently blank. I also need to relocate the switch for the rear wash/wiper as that's just hidden away at the moment as the wiper doesn't work. I might try and squeeze a CB in at some point and also a tablet mount, ipad sized - the structure is sturdy enough that I can use the self tapping screws to attach the frame too. Quote Link to comment Share on other sites More sharing options...
western Posted January 26, 2014 Share Posted January 26, 2014 If anyone can recommend a hole saw that will cut 52mm holes in metal can't recommend but there are lots out there in workshop tool land & on ebay https://www.cromwell.co.uk/QMX0451122T http://www.ebay.co.uk/bhp/52mm-hole-saw http://www.theminiforum.co.uk/forums/topic/177311-52mm-or-50mm-holesaw-for-52mm-gauges/ mentions the DART brand cutters. http://www.amazon.co.uk/Morse-Master-Cobalt-Metal-52mm-2-1/dp/B000E8BFFW http://www.buybrandtools.com/acatalog/Hole-Saw-Cutters-Starrett.html Quote Link to comment Share on other sites More sharing options...
mmgemini Posted January 26, 2014 Share Posted January 26, 2014 I have a set of hole saws but I'm not impressed. I still think the multi small drill idea then the half round file is best Quote Link to comment Share on other sites More sharing options...
JeffR Posted January 26, 2014 Share Posted January 26, 2014 I have a set of hole saws but I'm not impressed. I still think the multi small drill idea then the half round file is best With you on that one! Tried various brands over the years and quite frankly they didn't impress. Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted January 26, 2014 Share Posted January 26, 2014 I tend to find hole saws very good but people dont know how use them, much the same with drill bits. Quote Link to comment Share on other sites More sharing options...
mmgemini Posted January 26, 2014 Share Posted January 26, 2014 I tend to find hole saws very good but people dont know how use them, much the same with drill bits. Well please give me a lesson. 1 Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted January 26, 2014 Share Posted January 26, 2014 low RPM, lots of feed. Quote Link to comment Share on other sites More sharing options...
steve b Posted January 26, 2014 Share Posted January 26, 2014 Yep low rpm is key , std pillar drills are way too quick , a handheld with low gear and speed control trigger does the job. Needless to say holding it square to the sheet is also important to avoid breaking thru on one side of the cut first. I have snap on and bahco holesaws and they are both good . nice dash btw cheers Steveb Quote Link to comment Share on other sites More sharing options...
mmgemini Posted January 26, 2014 Share Posted January 26, 2014 Some of us, like me, don't have that option. Yes the old fashioned hand turned and hand fed pillar drill is one of the best. I've not found one though Quote Link to comment Share on other sites More sharing options...
studmuffin Posted January 26, 2014 Share Posted January 26, 2014 Rich, I used a nibbler that fits onto my cordless drill, but you need to drill a hole first and need to use 2 hands to guide it, so the steel must be held securely. I got it from Accord Roof Sheets in Kingswinford, about £25 plus p&p. Tried it on steel and rolled brass and its pretty good and you can guide it to cut pretty intricate shapes. Not as accurate as a tank cutter but I think you could get within 1mm, if this would be close enough. Quote Link to comment Share on other sites More sharing options...
ballcock Posted January 26, 2014 Share Posted January 26, 2014 If you make a suitable sized template then your plasma cutter should make short work of them with a little tidying with a file. Quote Link to comment Share on other sites More sharing options...
Lewis Posted January 26, 2014 Share Posted January 26, 2014 By far the best tool for cutting true 52mm holes for guages is a Q-max cutter https://www.cromwell.co.uk/QMX0451122T The holes produced are dead size and beveled to one face, there are no special tool required besides the cutter itself. I'd highly recommend them for this purpose Quote Link to comment Share on other sites More sharing options...
mikec Posted January 27, 2014 Share Posted January 27, 2014 I use the bosch powerchange holesaws, used loads of them and cut through 13mm steel with them but they wouldn't do a perfect 52mm hole in thin steel tho, same here low rpm and I use water constantly on them yep not ideal but its cheap and works Quote Link to comment Share on other sites More sharing options...
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