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