cutting dash Lens

[el_gureo]

I'm looking to install a PSI gauge in my dash in the empty dash pod and was wandering the best way of cutting a hole in the dash lens. Of course I don't want to crack or break the lens. what method to use?

[FRENCHBLUE72]

Dremel with a cut off wheel..

[suville]

If you are wanting to cut a round hole I would suggest a hole saw in a drill press you could also just use a hand drill but it will be a bit more challenging. Place the lens on a piece of wood and secure it with blocks of wood around the edges securing the blocks with screws and use as slow a speed as you can and go slow the plastic will get hot and instead of cutting it will melt make sure you cover the lens with wide masking tape to keep from scratching it up.BTW you have disassembled the gauge cluster I would assume dont know how you could do it any other way.

[DZL1]

Originally Posted by suville

If you are wanting to cut a round hole I would suggest a hole saw in a drill press you could also just use a hand drill but it will be a bit more challenging. Place the lens on a piece of wood and secure it with blocks of wood around the edges securing the blocks with screws and use as slow a speed as you can and go slow the plastic will get hot and instead of cutting it will melt make sure you cover the lens with wide masking tape to keep from scratching it up.BTW you have disassembled the gauge cluster I would assume dont know how you could do it any other way.

I agree with Suville except for one thing. If youre gonna use a drill and a hole saw, put the drill in REVERSE, that way the teeth of the hole saw wont bite down and kick the drill and possibly damaging your lens. Once the hole saw starts melting the lens you can then switch to forward. I would use a drill with variable speed so that way you can start of slow and work your way up to full speed. I speak from experience. Hope this helps.

DZL1.

[petey-pablo]

Can't you just wipe off the markings on the Dash lens with some type of cleaner without causeing it to haze or damaging the plastic lens, another thought would be polishing the markings away and put PSI gauge in from the back?

[Hatdcorechevynut67]

Just an added note to what dzl1 suggested. In order to protect your lens, tape it up using removable masking tape blue or green works well. It won't protect if your bit walks on you but it will keep minor scuffs and scratches down. Just a note: if you want to try and buff it out if the scratches aren't too bad. The plastic headlight restore kit works well on that kind of plastic. Good luck A.J.

[mbgmike]

I've cut a lot of plastic in my life up to 2" thick down to 1/16". (LExan and Plexiglass) Like stated use a drill press and lay it flat. If you have some double sticky tape, Tape it to a flat piece of wood. I would use a Fly cutter but they kind of scare some people. That way you can get the exact diameter you need. The fly cutter is adjustable. Go slow on speed and feed. The cutter will cut the plastic not melt it and you have a nice clean sharp edge with no flashing. You use the cutter with the flat towards the direction you cut if not familiar with it. You will know when its right. No need to clamp it down (unless you want to) just lay one hand on the board and use the other to lower the cutter. carefully pull up plastic from wood.

Just for info they do make plastic drill bits. much steeper angle then a twist drill. Not in that diameter however.