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:
