Custom switch panel

This post is on the customized switch panel that I fabricated using fiberglass and acrylic.

I will try to explain in sequence the steps on how I made the custom panel.

Step 1
Using a piece of acrylic as the faceplate of the panel, measure and cut holes for the toggle switches. I am using lighted LED switches.

Step 2

Once the holes for the switches are cut, shape the outer edge of the faceplate.

Step 3

Using styrofoam, shape the body of the panel to the desired shape. First start shaping using a sharp knife and styrofoam cutter (the hot wire type) and later refine the shape using a coarse sandpaper i.e. 400grit.  

Step 4

Once the desired shape is achieved, cover the styrofoam with masking tape thoroughly. Next, cover the item with a thick cloth. Any thick cloth that could soak resin will do. To make sure that the cloth sticks to the item, I used a thin double sided tape. Then mix the fiberglass resin with the hardener in small quantity (the resin will react and harden quickly and mixing too much might be wasteful) and apply the resin onto the cloth. Depending on the temperature and qty of hardener used, it may take up to 1 hour for the resin to harden.

Step 5

After the resin has hardened, mask and attach the acrylic faceplate and then apply the fiberglass putty. Apply and shape the putty making sure that the edge connecting the body to the faceplate is flushed.

Step 6

Once the putty has dried, sand the item smooth with a file and followed by coarse sandpaper.

Step 7

I finally wrap the item the carbon sticker and painted the sides of the acrylic faceplate a flat black colour.

These switches connects to the customized relay banks in my earlier post. I am currently using one switch to trigger my SPAL fan that I had mounted in front of my radiator to aid in the cooling process.

14 inch SPAL fan

Fan mounting process

Custom Relay Panel

Hi All,

Wow..it's been more than a year since my last post.

Will try to update more often. Today I'll just share with you the customized relay panel that I have made for the car. The main purpose for this mod is that I wanted a cleaner look for the relays that I was going to use to power the accessories that I have in mind. After researching in Google, I bought the necessary items online and at the infamous Jalan Pasar.

It all started with a blank piece of acrylic that I bought at a hardware store in Bangi.

The piece of acrylic after cutting and drilling holes

After carefully planning the layout of the relays, fuses, wire terminals and wire routing, I drilled holes in the acrylic for the wires to go through. The idea is to have the wires tucked in behind the panel for a cleaner look. Each wire is routed behind the panels using rubber grommets. 

These are the end result...

Front view

Rear view

Due to the lack of available space in the engine bay, the only available option to mount the panel was on top of the battery. This location also enabled me to have the live wire from the positive terminal to the fuses to be as short as possible, an important safety precaution in case of a short circuit.

This relay panel is activated by a switch panel inside the car which I am currently using to power my 14 inch SPAL fan. 

I will include the information of the switch panel in my next post..