Building a Custom GMC Dash Bezel from the ground up :).
 

Hey all,

Thoughts I'd document my quest to build a custom GMC dash bezel. Looks like a few companies out there make aftermarket plates where you can get the gauge configuration to your liking, but it seems like all of them require that you have an original bezel to hack up and use for the trim piece.

My goal is to create something that could be used standalone, without having to hack up an original piece.

I'll either be printing it, or milling it from plastic block. For my truck, I'll be routing some carbon fiber as the background to give it a little pop.

Here is what I've done so far:

1. A forum member was kind enough to send me an original piece I could measure. I took measurements, but also scanned the piece on a regular scanner, and then drew out the outside path in Illustrator:

http://i1037.photobucket.com/albums/...ps5vo7rrzx.png

2. Next I imported the outline into sketchup, and starting building the model around the outline. I used a digital micrometer to get as close to the original specs as I can. That said, there are some tapers here and there I didn't include, hoping they won't be critical to the end-fit. If they are, I'll modify and print again.

http://i1037.photobucket.com/albums/...psk954bja1.png

3. With the outline to scale, I started thinking about gauge placement. I also wanted to include a New Vintage indicator set, so I made a space for that:

http://i1037.photobucket.com/albums/...pstfcfeys6.png

4. From there I added spaces for my other 4 gauges, colored the plastic areas black, and the carbon fiber with a carbon pattern:

http://i1037.photobucket.com/albums/...psywkurw5a.png

5. Then I cut and paste my gauge faces for a final mockup.

http://i1037.photobucket.com/albums/...psnmzjljcb.png


Next steps:

My machine should arrive 1 week from today. It'll take me awhile to set it up and learn the ins and outs, but hopefully in the next month or two at the latest I can begin printing prototypes to test-fit.

I intend to update this thread as I make progress :).

Cheers all!

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

That is going to look great.
I am thinking about doing that in Engine Turned Stainless unless I find a manufacturer who makes it already.
Keep up the posts.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Thanks! Engine turned stainless would look awesome! Once I get a working/fitting 3d model I could send you the file if you can find someone who would mill it from steel.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

That looks good :thumbs:

Is that the free version of Sketchup? I have never tried 3d CAD yet.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Yeah I'm just using the free version right now. May upgrade if it hits some limitations but so far so good. I find it pretty easy to work with once you have the basics down. Should dive in cap.
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Re: Building a Custom GMC Dash Bezel from the ground up :).
 

That looks great, wish I had half the talent most of you guys do. Joseph

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Thanks sanford! I'll likely add some accent details to it soon and update the thread.

There are some truly talented people on this forum. Perhaps if I can actually build this, rather than just build it on a computer, I'll be able to call myself one of them ;).

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I really like what you’re doing, and the lower section built in below the gauges if you can actually pull that off. I did several flat panels in the beginning years ago, changing them to improve functionality as I moved forward.

Here’s what I started with, the ugly original gauge plate:

http://imagizer.imageshack.us/v2/xq90/684/015eds.jpg

And this was my first change. It looked nice, but I couldn't see half of the gauges:

http://imagizer.imageshack.us/v2/xq90/696/039yf.jpg

Followed next by this layout. Unfortunately, the panel was also ugly so it was changed again:

http://imagizer.imageshack.us/v2/xq90/14/003yucl.jpg

http://imagizer.imageshack.us/v2/xq90/811/126n.jpg

Here we go again with a different layout:

http://imagizer.imageshack.us/v2/xq90/233/3and4.jpg

http://imagizer.imageshack.us/v2/xq90/207/007vm.jpg

Ultimately I added a sculptured panel on top of the flat panel to more closely simulate the original panel. I added speed nuts to the rim in order to remove and install the panel without chipping the original paint on the dashboard.
http://imagizer.imageshack.us/v2/xq90/59/dash01.jpg

http://imagizer.imageshack.us/v2/xq90/855/dashpanel.jpg

http://imagizer.imageshack.us/v2/xq90/404/tuft04.jpg

http://imagizer.imageshack.us/v2/xq90/908/ACzimH.jpg

I’m not suggesting any of these ideas should be considered, just showing the stages I went through in finally arriving at a plan that worked in my installation.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Love seeing the iterations of your panels Mark! Question: What did you use for the outer part of the bezel? Was it the plastic from the original?

I shouldn't have any problem including the lower area built in below the gauges. I ordered the actual indicator/light set today so I can get exact measurements for it. Whether I print or mill I should be able to include that area.

Do you think I'll have any visibility issues with my layout? Perhaps hard to know without having it in front of a steering wheel lol. Maybe I'll do some dry runs in cardboard to ensure I'm not building something I'll immediately want to change.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I don't think you'll have any visibility issues with your gauges or your stuff at the bottom. It will be even easier if you have a tilt column, but I eliminated mine as it just wasn't really needed any longer.

I never had a plastic original bezel to work with. Mine was always metal, and as a result it always chipped the paint from the dash when being removed. That's why I cut the rim off mine and screwed it to the dash opening. This way, I could add and remove the face plate without scraping anything up.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Gotcha!

Where did you get a metal trim piece? Were some originally metal?

Depending on the fit of the one-piece solution maybe I'll consider doing what you did, and make the outer rim as a separate piece with tabs to screw the face plate into.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

The metal rim/baseplate was stock on the 1960-61 at least. I'm not sure when they switched to plastic. I just trimmed the center out of mine, added slip-on sheet metal nuts around the edges, and screwed the face plate to it. I would imagine the same approach would work with the plastic item as well, if there is enough thickness to hold sheet metal screws around the edges.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Yeah I think it would, and would certainly be easier to make custom plates. I'm not sure how available original units are, which is why I'm trying to make a nice one-piece replacement unit.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

1965 GMC Option booklet.
https://lh3.googleusercontent.com/-I...c42/image8.jpg

1964 GMC Option Booklet.

https://lh3.googleusercontent.com/-X...2/image0-4.jpg

1960

http://67-72chevytrucks.com/vboard/a...1&d=1247411695

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I think you will probably have your steering wheel in "line-of-sight" directly over your four smaller gauges...:smoke:
You will probably have to reverse their positions like Mark did in his 2nd version to make it work absent a tilt column. ;)

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Just a small update

CNC Router has been built and I am currently dialing it in. Cut a few pieces of pine last night, and tomorrow am picking up some foam I can quickly zip through to prototype fitment of the gauge piece. I'll send photos once it's cut out, and of how it fits into the dash opening.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Just like the Heinz commercial " Anticipation"

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I have that metal cluster piece and don't need if you want it. I know you said you took measurements but if you need to own one let me know.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

A kind member sent me a plastic one they had available, so I was able to get all the measurements I need off that. Next steps are to let the machine build one in foam and test fit. Then I can trim the foam manually where needed, re-mic it, update the design, and carve out another.

Once the dimensions are solid I'll add some more design details, rebuild in foam, and verify my toolpaths look good on the machine. Then I'll throw in a big hunk of plastic and carve it out as one piece. From there I can iterate on whether or not making it a two piece is beneficial, as some people have mentioned that the trim ring scrapes paint taking it in and out, so if the trim could stay in place while the backing separates that might be handy.

Two pieces might be better if I was going to make these for others, as then it would be easier to select backing material (wood, carbon fiber, aluminum, plastic). My fear is that the ring in plastic might be too frail to stand alone, but we'll see.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

A night of great progress

Didn't get started until around 8pm or so tonight, but made some great progress on this project. I picked up some 1" insulation foam at the hardware store to do a test run of the design. Worked great. After it was cut I compared it to the original. Very close in size, but not there yet.

I made a rookie mistake. When I drew the profile line of the design, I think moved OUTWARD from that line for the trim ring, rather than inward. As such, my design is too big by exactly the size of the trim ring. I need to swap the trim ring to be on the inside, and it should be nearly an exact fit.

I also didn't mill the inside as deep as the final design to save on cutting time, since I'm primarily concerned with outside size fit at the moment. Will try again in the new few days and then test fit. I also used a 1/4" bit for the entire thing, so some of the rings couldn't be fully cut due to the distance being less than 1/4" between pieces inside. But for now, some eye candy:

http://i1037.photobucket.com/albums/...psha6zpupq.jpg

http://i1037.photobucket.com/albums/...ps1cg3jdzl.jpg

http://i1037.photobucket.com/albums/...psufzkyapo.jpg

http://i1037.photobucket.com/albums/...ps8ohq0gwt.jpg

http://i1037.photobucket.com/albums/...psw8usvhcv.jpg

http://i1037.photobucket.com/albums/...psfr0ytktq.jpg

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Eye Candy is right, nice start.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I love seeing things like this that guys are doing at home. I wish I never had to get rid of my CNC Plasma table...someday I will get another smaller one for my shop...

Can't wait to see more progress!

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Thanks guys. Will try and resize and carve another one tonight. If I can do it early enough I'll test fit on the truck too.
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Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Fitting better

So I had a bit of time to work on the project tonight. I scaled down the design a bit and routed just the outside pattern to see if I got the fit. I think it's right where it needs to be. BUT, as I mentioned before it does not have the taper of the original cluster, and I haven't test fit yet to know if it needs it. If it does it will mean I need to do some redesign and mill both sides, which means the mill time will go up by 50-60% and become more complex.

Perhaps someone out there knows . . . is the taper on the original dash cluster needed? Meaning, does the opening in the metal dash a taper fit? My memory is saying it might be, but my truck isn't in the garage and it's been awhile since I've been in the cab.

In any case, here is how the cutout aligns with the factory cluster housing:

http://i1037.photobucket.com/albums/...psllh6olv8.jpg

http://i1037.photobucket.com/albums/...ps3w7k4ict.jpg

http://i1037.photobucket.com/albums/...pstdtknkgt.jpg

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I don't believe it needs the taper all the way around only in the area where it mounts. I have my truck in the yard with dash out so I'll check it out and drop some pictures in the morning. Are you going to be willing to make these for other members with the GMC cluster? If so would you be willing to try eight gauges?

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

I'd be willing to make them for others yeah. Once I'm done I'll figure out material costs, machine time etc and if members think it's worth it I'll get a vendor license and create a thread for them. And yeah other gauge configs shouldn't be too hard.
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Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Hi Sorry for the delay. I had a hard time getting a good picture that shows the taper. So basically the bottom is flat but the top and side have a good taper.


My gauges:

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Are the tabs that hold the bezel in threaded, or is it supposed to fit via the taper wedging it in, and pins through the 4 tabs not letting it come out? If it was threaded it would be a lot easier, as the bolts could hold it in place, and the taper wouldn't have to be exact fit. Looks like I see nuts on them, so that might work . . .

I'm going to test fit tonight, and will try and do 2-sided milling to get some taper in there tomorrow or Friday.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

The tabs are not threaded but do have j-nuts. I was envisioning pins holding in the top and you would reach under the dash to screw in the bottom.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

More good progress

Hey all,

Just wanted to update this thread. So I am about 99% done with the fit, including the taper. I think I need to adjust the taper a few degrees, and shrink the outer size by a hair. But I got a snug fit in my GMC dash with the foam outline piece. With the finished piece being a harder material, I want to shrink it a bit since the foam may have compressed slightly going into the cutout.

http://i1037.photobucket.com/albums/...psoaep6j7o.jpg

http://i1037.photobucket.com/albums/...pshjslnuaw.jpg

Also, I did my first attempt at building the vectors/cutouts I needed for the New Vintage indicator piece that I bought, and I think I pretty much nailed it on the first try. I cut it into a scrap piece I had upside down, so in my design it will be on the bottom, though after seeing the design I may flip it and put it at the top of the gauge cluster. The only change I need to make is to recess it about a 1/16th-1/8th more so it's flush and the back threads have more room:

http://i1037.photobucket.com/albums/...psku4vngtj.jpg

http://i1037.photobucket.com/albums/...ps24lseswv.jpg

I'll be taking my 4'x2'x1" plastic sheet and making it into 1'x2' sections today I think so I might be able to do a full prototype in the finished material today or tomorrow.

Stay tuned!

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Minor updates

I am going to try splitting the design and make it a modular unit. I am going to separate the trim ring from the back piece, and will split out the New Vintage signal piece as yet a 3rd piece that will all bolt together.


This is for a few reasons:

1. It will allow me to use different backing materials without having to re-mill the entire unit.
2. I can use different processes that might be more suitable for each piece. Due to the taper on the back side, I have to mill both sides of the material, meaning if I am slightly off when centering I ruin the whole piece. Not an issue for the pros, but for me, I can see it happening and suddenly a $40 piece of plastic is ruined.

So the new processes, in theory, will go as follows:

1. I will 3D print the trim ring, which will handle the taper and I can print in tabs that a backing plate would screw to.
2. The backing plate can then be milled from plastic, wood, aluminum, carbon fiber, etc based on preference.
3. The turn signal holder can either be printed or milled. In thinking ahead of potentially productizing something I am making it a separate unit so someone could add it remove it and not have to buy a whole new setup. This will also bolt to the trim ring and through the backing plate.

Designs to come, but I should have all the material coming I'll need to print a prototype trim ring by the weekend.

Progress is slow but steady!

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Updates:

Hey all,

It's been awhile since I have had a chance to work on this, but was able to get a few hours in over the holidays.

I haven't been able to get a good 3D print of this size going. Unfortunately I think the method I detailed above isn't going to work with the equipment I have.

However, I still think milling it as one piece is a viable solution, so I have begun that route again.

I started by finding the exact center of the workpiece, and then drilling two holes, one at center/center, and the other at center/bottom. I drilled it through the material and into the spoil board so that I can flip the workpiece over to mill the back side and ensure it's in the same location as before.

My overall design consists of 8 toolpaths:

1. Indicator area pocket (for turn signal/engine light bezel to sit)
2. Indicator area cutout (so the wires can come out the back of the housing)
3. Info panel pocket 1 - this is where the center hole is. I'm going to mill an aluminum plate here that says something like "GMC - Premium Unleaded Only" to add some detail to the panel as well as cover the center locating hole
4. Info panel pocket 2 - This creates the pocket for the aluminum plate to sit in
5. Gauge pockets - This mills away about .75" of material everywhere but where the gauges go and the indicator/info panels go.
6. Gauge cutouts - This cuts away the material in the center of the gauge areas so a gauge can actually go in.
7. Gauge pocket 2 - This reduces the material on the rings around the gauges, so the gauges aren't flush with the outer trim ring, but instead sit about .25" off the back panel.
8. Panel taper and profile cut - This path does the taper on the back side, and cuts out the entire piece, freeing it from the source material.

Lots of info, and all hard to imagine without photos, which I'll add to this later so you can see how it's made.

I went ahead and cut the first 4 paths in the material and did a test-fit with the indicator panel, which fit great.

Here are a few photos, but again I'll add more later when I'm home.

I expect there is another 2-4 hours of milling, but I am taking it slow as I'm still learning the right feeds and speeds for the machine.

http://i1037.photobucket.com/albums/...pspe5sakzf.jpg

http://i1037.photobucket.com/albums/...pskkm3skyj.jpg

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Nice update!

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Cluster for my 64 GMC

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Looking good!

Wish I had that talent.

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Looks great 64Chevy! Originally I modified my stock cluster, but at some point there was only so much I could do to make it work for me. I'm hoping to build a stand-alone unit so I don't have to keep finding/modifying stock clusters. That way there are more original units out there for people who want to go the classic route :).

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

Incremental progress. Been busy at work, but managed to finalize the indicator pocket design and size. Used the scrapped piece to finalize. The actual pocket will sure about 1" north of where it is now.
http://i1037.photobucket.com/albums/...psn9z9vjyd.jpg
http://i1037.photobucket.com/albums/...pse9walpmj.jpg

Re: Building a Custom GMC Dash Bezel from the ground up :).
 

How did this project turn out! Looks awesome!