Suggestions for building a dash panel

[G-Rex]

Ok, so....against my better judgement, I'm going to solicit y'all for suggestions. I'll preface by saying there is NO room behind the dash, or under the existing fairings in places where they are easily accessible.

I want to add two knobs for my Gerbings heated gear, a volt gauge, and two accessory switches for, um, stuff.

I'm considering an ABS plastic dash panel of sorts. What I envision is similar to the cardboard mockup in the photos. I'm going to want the unit to be enclosed and water resistant. I will need one opening for the wire harness to run through but that's not my concern right now.

The cardboard piece I mocked up obviously doesn't have a bottom or back on it, but the face and top, are generally what I'm looking for. I'd *like* to follow the contours of the dash panel as best as possible. Average dimensions are 9" wide, 2-1/4" tall, and 1-3/4" deep.

What I'm looking for is feedback on how in the hell I can form a piece of ABS to make what I want, suggestions for other material, or just any other idea in general to get to where I want.

[OneSickPsycho]

Fiberglass?

Otherwise you could probably form it with a heat gun and some patience...

[G-Rex]

I have the heat gun. Patience, not so much.

Fiberglass might be an option. I'm going to go look at Hobby Lobby today for some high density foam that I can use to begin carving a replica of what I want, at least externally.

[askmrjesus]

You could fab it up out of aluminum pieces, (easy to bend) put them together with small nuts and bolts, and then JB weld the seams, sand and paint.

JC

[derf]

That was my thought, either a fiberglass enclosure, or an aluminium one with silicon sealant to keel it water tight.

If the piece of aluminium is large enough, cut it out to include, sides, front, back top and bottom, then fold it over , pop rivet it to iteself with silicon to seal it , fill in any gaps with JB weld, sand and paint

[Homeslice]

The other question is, what are you going to mount it on. Is there a metal fairing stay near that area?

[G-Rex]

Originally Posted by Homeslice

The other question is, what are you going to mount it on. Is there a metal fairing stay near that area?

There are two bolts holes on the bottom side that joins the dash panel to the cover for the windshield adjustment motor/track. Whatever I come up with will attach there. On the top side, it doesn't show up real well in the photos I attached, but there are two plastic *buttons* on either side for lack of a better term, that I am going to remove and replace with studs, or place nuts and bolts through to support it from the top side.

[Hydrant]

You can weld plastic with a plastic welder. Get some plastic panels and weld them to whatever for you would like. (It's tough to figure out)

http://viewer.zmags.com/publication/...#/3f0390ad/592 There is an example of some sheet plastics and rod.

This is who I get some of my plastic material from
http://harringtonplastics.com/ look through there for some info.