Fiberglass Cutting

[JCS]

I plan to remove the 3 push pull and 1 push button horn switch on my dash and replace them with a single 4 switch rocker switch panel in red to match the rest of my dash.

My question is currently there are 4 holes drilled into the dash for the current switches. I now need to cut a rectangle large enough to fit the 4 rocker switches but small enough to be covered by the new panel. What would you recommend I use to cut the dash?

I have one of these tools. http://www.ryobitools.com/catalog/power_tools/cordless/P340

Any suggestions??

 

[NEBS]

I would use a jig saw with a fine blade. You will be cutting though gel coat over plywood. Hopefully the switch panel came with a template. If not I would make a cardboard cutout and use that as a template to get the right size hole. Before cutting use that blue painters tape to protect gel coat from tool marks. Probably need to drill holes in corners. You only get one chance.

 

[keith4216]

Sounds like u just need to enlarge the hole. There's lots of tools that u can use. I think I would mark the opening with a sharpie then use a die grinder to open it up. Have someone hold a vacume hose while cutting to catch most of the glass dust. Or the above post is good also

 

[groundloop]

What I've done is first cover the area with painter's tape to prevent any unwanted scratches. If where you're cutting has wood under the fiberglass then pretty much exactly as Nebs suggested, a fine toothed blade on a jig saw. If it's an area without wood then a diamond blade on a die grinder (if there's room to maneuver it) or else a dremel tool with a diamond cutoff wheel (Harbor freight sells these).

 

[jazzy]

if you want to do it right, use a router and a jig

 

[bigredinohio]

What I've done is first cover the area with painter's tape to prevent any unwanted scratches. If where you're cutting has wood under the fiberglass then pretty much exactly as Nebs suggested, a fine toothed blade on a jig saw. If it's an area without wood then a diamond blade on a die grinder (if there's room to maneuver it) or else a dremel tool with a diamond cutoff wheel (Harbor freight sells these).

x2

 

[JSmitty]

I used the Harbor Freight version of your Ryobi. Worked perfectly. Very precise. No setup time required except for drawing a line where you want to cut. A metal cutting flat blade works best on fiberglass. If the friction starts making the wood behind the fiberglass smoke, just back off and plunge a little at a time.

 

[JCS]

I made a template so I could prepare to cut the section for the switchs, I taped the area of as suggested and while there tried my cutting tool. Using the steel cutting blade it didn't really do well cutting the dash. It seems the jigsaw is the way to go!

 

[JSmitty]

I'd be very careful with a jigsaw. It looks like you have absolutely no leeway on the sides of that switch panel for mistakes. You might want to do as Keith suggested and finesse the opening with a die grinder after doing a rough cut with a jig saw. The small pneumatic grinders are particularly precise. The bigger electric ones, less so

A router would work too, but only with a jig. No way you could freehand that tolerance.

With those tight tolerances, whatever blade or bit you use, make sure it's a very "fine" cutting one. Some chipped gel could easily show on the sides of that panel.

Not sure why your Ryobi didn't work. My HF blade went through the dash like a hot knife through butter.

 

[JCS]

There is actually room for error on the cut. I'm only cutting space for the connecting side of the switch to fit through. The plate overlays the cut, my plan was to do a rough cut then use a dryel tool to clean it up.

 

[JCS]

Final Result

I finished the cut, used a combination of a jig saw, my multi cutting tool and finished the cut with a Dremel Tool with a cutting bit (mini router).

BEFORE

AFTER

 

[JCS]

BEFORE

AFTER

 

[JCS]

BEFORE

AFTER

 

[JCS]

Sorry guys I can cant seem to get these pics to post.

 

[JCS]

BEFORE

AFTER

 

[JCS]

Try it again but larger.

Before



After

 

[RNGRDVE]

Looks good. Much more modern appearance.

 

[NEBS]

Looks nice. It can be a little intimidating cutting through the helm. I had to cut a hole for a stereo on the passenger side. Came out fine. Just have to take you time and line everything up.

 

[keith4216]

MUUCCHHHHH nicer!

 

[JCS]

Thank you, I liked the result, more up to date appearance.