Drive Stainless
06-04-2016, 02:50 PM
Brought to you by 43438
Tools needed:
1. Heat gun
2. Metal bending brake - I used the 18" #39103 Harbor Freight brake w/ C-clamps
3. Drill press w/ 3/16" and 3/8" drills
4. Table saw or similar
5. Two nylon spring clamps - I used HF #69291.
6. Tape measure
7. Masking/painter's tape
Materials needed:
1. 1 sheet of 0.093" acrylic cut (using table saw, etc) or sized at 17" x 6.75"
2. Your old scratched-up instrument cluster lens
Procedure:
Once you have the sheet sized at 17" x 6.75", cover the whole thing with masking tape to prevent any scratches during the remainder of the procedure:
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Mark off 9/16" from each of the LONG ends, and then also mark 1/16" closer to the EDGE. Locate the brake bar at the 9/16" mark, and the brake *seam* on the 1/16-closer-mark.
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Now clamp it down and heat up that edge with the heat gun as you begin to bend it to approximately 45 degrees. You will know when you've gone far enough when you can slip a 13mm box wrench vertically under the handle to prop it in place:
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Leave the brake propped in place while it cools. LET IT COOL COMPLETELY! If you pull it out too soon, the lens will distort like a potato chip. It will take about 20 minutes.
Now do the other end, bending in the opposite direction:
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Prop it in place and let cool for another 20 minutes:
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Now clamp the "new" lens on top of the old lens using the two nylon clamps. Using a drill press and using the the old lens as a drill guide, drill all of the 3/16" holes. Drill a 3/8" hole for the trip-o-meter reset button. You will want to drill the 3/8" trip-o-meter about 1/4" HIGHER (toward the roof of the car) than the template would suggest. I do this by drilling a 3/16" hole at the TOP of the template hole, then removing the clamps and the old lens, and enlarging the hole using the 3/8" drill bit.
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You will need to trim the lens at the bottom and possibly the top corners so that it fits within your binnacle. This can be done before or after you remove the masking tape/plastic (if you're careful).
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The END!
Note: Polycarbonate is another material that can be used in this application. Polycarbonate does not require heating in order to bend it using the brake. The disadvantages to polycarbonate are that it scratches more easily, turns yellow with exposure to UV, and costs more.
Tools needed:
1. Heat gun
2. Metal bending brake - I used the 18" #39103 Harbor Freight brake w/ C-clamps
3. Drill press w/ 3/16" and 3/8" drills
4. Table saw or similar
5. Two nylon spring clamps - I used HF #69291.
6. Tape measure
7. Masking/painter's tape
Materials needed:
1. 1 sheet of 0.093" acrylic cut (using table saw, etc) or sized at 17" x 6.75"
2. Your old scratched-up instrument cluster lens
Procedure:
Once you have the sheet sized at 17" x 6.75", cover the whole thing with masking tape to prevent any scratches during the remainder of the procedure:
43429
Mark off 9/16" from each of the LONG ends, and then also mark 1/16" closer to the EDGE. Locate the brake bar at the 9/16" mark, and the brake *seam* on the 1/16-closer-mark.
4343143432
Now clamp it down and heat up that edge with the heat gun as you begin to bend it to approximately 45 degrees. You will know when you've gone far enough when you can slip a 13mm box wrench vertically under the handle to prop it in place:
43433
Leave the brake propped in place while it cools. LET IT COOL COMPLETELY! If you pull it out too soon, the lens will distort like a potato chip. It will take about 20 minutes.
Now do the other end, bending in the opposite direction:
43434
Prop it in place and let cool for another 20 minutes:
43435
Now clamp the "new" lens on top of the old lens using the two nylon clamps. Using a drill press and using the the old lens as a drill guide, drill all of the 3/16" holes. Drill a 3/8" hole for the trip-o-meter reset button. You will want to drill the 3/8" trip-o-meter about 1/4" HIGHER (toward the roof of the car) than the template would suggest. I do this by drilling a 3/16" hole at the TOP of the template hole, then removing the clamps and the old lens, and enlarging the hole using the 3/8" drill bit.
43436
You will need to trim the lens at the bottom and possibly the top corners so that it fits within your binnacle. This can be done before or after you remove the masking tape/plastic (if you're careful).
43437
The END!
Note: Polycarbonate is another material that can be used in this application. Polycarbonate does not require heating in order to bend it using the brake. The disadvantages to polycarbonate are that it scratches more easily, turns yellow with exposure to UV, and costs more.