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Old 12-30-2013, 10:26 AM   #15
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Quote:
Originally Posted by Dunner View Post
The last time I checked, JB weld was a two part epoxy. For best strength, don't use the JB Quick.
I went by Home Depot last night to buy some products for testing. I did see the JB Quick product that's not the JB Weld I have at home.

Thanks for your input, Dunner

Rich
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Old 12-30-2013, 11:30 AM   #16
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Testing phase

Ok, the products that I'm going to test on scrap plastic and scrap metal are:

- Gorilla Glue
- JB Weld (2 part epoxy)
- Loctite (2 part epoxy)
- Solder
- Plastic

The Rivnuts look like a fantastic product, but, if I can get any of these tests below to work, I won't look to the Rivnuts for this project.

THIS IS A TEST. Please excuse the ugly pictures.THIS IS ONLY A TEST.

Last night, I roughed up all bonding surfaces (scrap metal, scrap plastic, and straps).

On the scrap plastic I used (from left to right) JB Weld, Loctite, Gorilla Glue, and then I melted scrap plastic with a soldering iron.



On the scrap metal I used (from left to right) Loctite, JB Weld, Gorilla Glue, and Solder.



I bought some fibreglass cloth and plastic/metal bondo that I am going to try also, but heading out of town today and won't be back until the week end, so I'll have an update then.

I'm going to leave the clamps on until I get back.

Anyways, have a safe and Happy New Year everyone,

Rich
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Old 12-30-2013, 11:49 AM   #17
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The only problem with the regular JB weld, is it tends to run a lot for hours. I usually have to reposition a part several time to get it to run to the right spot. For your use, it should not matter if it does as it's on a flat surface.
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Old 12-30-2013, 04:21 PM   #18
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Bolt it...

Start with thick panel so you can properly use counersink fasteners.

Next make cross pieces that extend past the sides of the hole.

Then apply something to the cross pieces to keep them in proper alignment.

Make top dressing cover slightly larger than the hole so it acts as lid.

Now the cross pieces go across the panel from the rear and stay in place.

Cover goes on top and is held in place by screws through the cross pieces.

End result is no holes in original dash so all can be undone and no glue to fail.

Use plexiglass to make pattern then aluminum for panel.
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Old 01-20-2014, 10:07 PM   #19
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Panel Update

I finished the fabricated panel a few weeks ago, but, I've been trying to match the color of the dash with mixing model paints and after a few different tries, I've settled for the color it is now.

The progress went like this:

I experimented with bonding metal to plastic and metal to metal.

For the metal to plastic, I tried JB Weld, Loctite(2part epoxy), Gorilla Glue, and melted plastic.





For the metal to metal, I used JB Weld, Loctite, Gorilla Glue, and Solder (I don't have a welder).





For the metal to plastic, the JB Weld, and Loctite didn't hold. Gorilla Glue held but it felt like, with a little bit of tension it would break off. I was liking how the melted plastic held (rigid).

For the metal to metal, the Gorilla Glue didn't hold, but, the JB Weld, Loctite, and solder held firm.

I opted to go with melting plastic. I melted a divot into the panel, Gorilla Glued the nuts in the divots, then the next day, I started melting plastic and formed it up into a cone shape.









This is what it looks like in the truck.




It doesn't match the color and the edges are not flush, but, it's solid, I can add 3 more switches (for a total of 8) to the panel (when I'm ready), and I like it. I will only be using 3 in the beginning (fog lights, back-up lights, and auxiliary power).

TQ60, thanks for your input, I liked the Plexiglas idea, but, I didn't have any scrap to use. I did take a plastic sheet from a paper binder and used that as a new template.

Thanks VanDiemen23, Sammie, rospradley, ronjhall, Mel, and Dunner for sharing your ideas and guidance.
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Old 06-22-2014, 03:14 PM   #20
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Thought I would give a thread update of Switch Panel

I wasn't content with the panel overlapping the outside of cubby hole. I did some trimming so the panel would fit inside the cubby hole.

I installed and wired up all the switches that would complete the panel.

so far, I'm only using 3 switches for Fog lights and Back-up lights.

Here's some pics.



















The panel is still not perfect, but, I am satisfied with how it looks now.
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