How to Make a Custom
Part
I need some switch panels for the overhead going into
my truck, I used my usual methodology, although this is a car
part, you can pretty much make up anything you need, within
reason, this way:
Draw the parts
in CAD and print at 100% size (my pattern sets are saved as
100%-sized *.jpg files, by the way) on paper. I decided
that square panels were boring, so I got kinda artsy-fartsy
with the mount tabs.
Then I used some blue masking tape to cover my 6mm PVC
scrap (I got this material just for begging a dumpster-dive
at
InterstatePlastics
, and it is a dead-on match for vicky
red, coincidentally) and then sprayed the back of my printout
with Super90 Spray Adhesive.
Note that I didn't spray the masking
tape- because any areas not the covered by paper would then
stick to my fingers and make cutting a pain instead of a joy.
(It's fun making your own stuff, when it doesn't include
bloodshed).
The tape layer allows EASY removal of the
CAD artwork after cutting. You could also use cheap contac
paper to do this, and I have had very good results with it.
Definitely mark
the hole locations in advance with a punch or similar item.
Drill bits walk around without a center
mark, even on a paper surface. Also, start with a tiny drill
bit, and 'pilot' all the holes first. Any error in drilling
will be MUCH smaller with a small diameter bit to start. Then
you can enlarge the holes later with a bigger bit, and it
won't wander. That way, all the holes will line up.
The part here has just been buzzed out
using a band saw:
I'll go back and
sand the edges, but the saw gets vary close to begin with.
That's a second pattern on top there,
waiting its turn at the knife.
Here's the
panel, minus sanding. The front row of switches is
test-installed at the moment. The other 16 switch positions
will have standard, un-shielded toggles. Maybe...
I like "Helicopter switches" a lot, and
know where to get at least a dozen
more.
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BUILDING
