17-FEB-2013
Hit the sander
I finished all of the edges and rounded the corners to the correct radius needed for this project.
17-FEB-2013
Making my stand-off frame
I had the metal supply shop that I bought this remnant aluminum from shear me a couple of 5/8" strips to be used as my framework for the perimeter of the panels.
I roughly marked the corners for my bends and bent the strips over a couple pieces of 1/2" and 5/8" round stock to get the radius I needed for my corners.
17-FEB-2013
Stand off frame complete
It took some time and a lot of shaping but I got the strips to fit on the panel pieces nice and tight. I need to cut some wider strips for the speedo panel because I have a step in the dash.
17-FEB-2013
Top view
The flush side of the panels. This is what I had pictured in my head.
17-FEB-2013
Glove box door
I cut a new door out of aluminum for the glove box which I was going to use as a cover on the newly shortened door to match the other new dash panels. After a test fit it looks like the aluminum won't be able to be used as a cover because when the door is opened there is not enough room for the aluminum to slide under between the door and the dash.
It looks like a change of plans is in order!
17-FEB-2013
Clamped up for welding
I clamped the heck out of the stand off strips to keep them from moving while I tacked them in place.
21-FEB-2013
Getting ready to punch the gauge holes
I using an electrical knockout die to punch out the gauge mounting holes.
This punches a 2" diameter hole and a 2 1/16" hole is needed so a little filing will be needed to finish the holes.
21-FEB-2013
Die set up and ready
I actually tested it on a piece of scrap aluminum to make sure that it wouldn't distort the metal.
21-FEB-2013
A 1" socket is needed
A few turns with the ratchet and a perfect hole is punched!
21-FEB-2013
Gauge holes complete
The four holes were punched with hardly any effort, now just a little bit of filing is needed so the gauges will fit in the holes.
21-FEB-2013
Speedo and tach holes
Unfortunately I don't have a 3 3/8" punch so I had to break out the jig saw.
Naturally I also had to use the jig saw on the radio cut out for the center gauge panel.
21-FEB-2013
One more gauge hole
I had to punch one more hole for the fuel gauge.