Almost two years ago, I bought a used Spec Boxster (SPB) race car. The previous owners had put a switch panel in the dash, and I added a couple of switches to it, but I was never really happy with it. Plus, I decided I really didn't like the red switch covers, but wanted something to protect the switches from accidental ons or offs.
Here's the original panel:
Click to view attachment So, I decided to make a new panel.
First, I cut a piece out of some leftover delrin and sized it in the mill:
Click to view attachment Click to view attachment I drilled the hole for the coolshirt switch and cut the squarish hole for the defrost button first, by hand. Then, I used the mill to drill holes for the toggle switches spaced evenly in between. I decided to drill holes for four switches, even though I'm currently using only two, just in case I need to add some in the future. I took advantage of the DRO to make sure everything was properly aligned.
Click to view attachment Click to view attachment So, here's the new panel with all the holes drilled and the surface sanded with 400 grit. Also, the extra holes around the toggle switches will be explained later.
Click to view attachment I also used new stainless steel button head screws to mount the panel, with a coat of flat black paint. The trick to painting small screws is to take a piece of cardboard and cut small x's in it with an x-acto knife -- then just push a screw into each x and the cardboard will hold the screws in place.
Click to view attachmentNow comes the reason for the extra holes around the toggle switches -- switch guards! The guards are made from 3/16" aluminum tubing, bent using a decent tubing bender. I made six guards, so I had a spare just in case.
Click to view attachment Click to view attachment Click to view attachment Next is cutting all the guards to the same length. First step was to make a jig to hold the guards, by milling slots into a block of wood for the jig. Then, each guard gets run through the mill to be sized.
Click to view attachment Click to view attachment Click to view attachment Then, the guards need to be modified so they can be mounted. Fortunately, the hole in the tubing is just the right size to be tapped for 6-32 screws. This turned out to be the biggest pain-in-the-butt step, since there were 12 holes to tap.
Click to view attachment Here's the initial mounting of the guards:
Click to view attachment Here's the final product; painted, labelled and mounted back in the car:
Click to view attachment