DSE Dash Insert help

[Todds69]

I was wonder what people are using to cut the holes for the gauges. I was thinking of using a jigsaw but I'm afraid it may bind on the 2-1/16 in. holes and warp the panel. Scott Gulbranson does a write up on it at Lateral-g, but didn't say how on the holes. I could call DSE but figured I would ask her first. Thanks Todd

[68sixspeed]

hydraulic sheetmetal knockouts if you can find a friend in the sheet metal or electrical trades; or next best bet is a good quality hole saw. (Home depot, lowes, etc, if they don't have the right size, try McMaster.com or www.msc-direct.com) -Dan

[toxicz28]

I wouldn't waste time in HD or Lowe's, they don't carry 2 1/16".

[yellowrallys]

Good name brand hole saws and a little filing. Cut out some card stock templates first and move them around on the dash insert to see where they look best, then centerpunch them and start cutting.

[Madspeed]

I used a 5" speedo and 5" tach and 4 2 5/8' water oil fuel and volts guages

I taped offthe insert figured best placement measured and drew all my lines for centers.

You will need to decide what guage you are going to put offset as the dash was not symetrical by about 5/16"

I went to a good tool supply house and bought Milwakee 4 1/2" and 2 5/8" hole saws (2 1/16" if smaller guages)

I carefully drilled smaller pilot holes then used the hole saws for start.

For the 5" tach and speedo you are going to need a drum sander on a Die grinder WITH CARE,
A dremel too will take you weeks to open up to the neededsize from 4 1/2"


I marked off the headlamp switchhole and drilled (no biggy)
The wiper switch I marked a line to cut a slot and drilled small pilot holes at each end the size of the Cutoff wheel I used to cut between them.

I put the switch in and marked 3 holes for it and drilled one then I used small 8 32 black button head allen screws and small spacers to screw the first hole and center the switch.
Then I driled the next hole bolted it together and did the third.
Next I unscrewed it all and fliped the swithc around to drill a 4th hole ( the switch only uses 3 screws , I used a 4th dummy srew for symetry)



Another VERY important Step I screwed up was the radio placement.
It is NOT centered. If you do center it you will have to cut the dash brace like my Dumbarse did so LOOK at your old cluster check doubble and tripple check it.

If your in need of any further assistance Pm me with your Phone number and Ill help ya out

Gl Ken F @ Madspeed

[Todds69]

Thanks a million guys I really appreciate it. I dont have the gauges yet but figured I could paste some circles out for placement. The bad news is I have four 2-5/8" liquid filled gauges but I want to swithc to the silver faced ones probably 2-1/16" and definately 5" tach and speedo. I hate buying things twice, or maybe I sould say I hate newer cooler stuff out that I really want.