1-DIN gauge holder for GQ

[patrol_maverick]

Here's a small project I made the other day that I'll share for anyone else who wants to make one. I needed a gauge holder for my boost & pyro gauges, but I didn't want a dash or pillar pod, so I made a gauge holder from tinted acrylic to fit in the spare 1-DIN radio slot. This is to suit GQ's, but would possibly fit GU's, etc too.






For anyone who wishes to make a gauge holder, I would recommend having a practice attempt by making one out of cardboard first, keeping in mind the dimensions provided are to fit my gauges above my radio. There are small variations in size between brands of gauges and radios, that's why it's best to practice before buying/ wasting plastics.

Trial fit the gauges in the holder, then trial fit the holder in your truck.

Once the cardboard holder is deemed suitable you can move onto the plastic gauge holder. I used grey tinted acrylic (Perspex) because I had some laying around, but ideally polycarbonate (Lexan) would be better. Acrylic can chip/ crack easily. Polycarbonate is way tougher and would be more ideal. Bunnings sells sheets of acrylic, but a plastic supplier would probably be cheaper.
Once everything is marked out correctly, start by cutting out the gauge holes first. I used a 51mm hole saw, then lightly filed the hole until the gauges were a snug fit.
**Ignore some of the lines, there was a change of design.

Next cut out the rest of the gauge holder, I used a jigsaw with a fine-tooth metal cutting blade. If you don't cut the large holes first, you risk cracking the base of the holder.

[patrol_maverick]

Now for the bending. The plastic needs to be heated in order to be bent. Acrylic will shatter if you try to bend it cold. Polycarbonate can be bent cold but it's best to heat it as it will give you a sharper fold.



There are commercially available heaters for bending plastic, but it's cheap enough to build your own. I bought a strip heater ($19.00) and 2 ceramic floor tiles ($2.50 each), both from Bunnings. All you have to do is assemble them as shown with a 5mm gap between the tiles. I had the gap above one of the heating tubes in the heater.


To bend the plastic, simply place it over the gap so the fold lines are receiving the heat. If you haven't done this before I would suggest practicing with some scrap plastic first. Too much heat will cause bubbling within the plastic, and not enough heat obviously won't allow the plastic to bend.
I used 2 rulers to help keep the bends straight while bending. Hold down one side of the fold with one ruler while lifting up under the other side with the other ruler (if that makes any sense without picts.


Bend the top first, then bend the sides in.


Use a straight edge to align the face of the holder & radio, then mark out and drill the locations of the side mounting holes.




Install the gauges into the holder, then install the holder to the radio brackets. Now you just have to fit the wiring & hoses and fit everything back in your truck.

Finished.

[patrol_maverick]

It's also worth a mention that the holder should be wide enough to take 3 gauges if you wanted.

[AB]

Very impressive mate, love the bending technique, I'll remember that one...

Looks very neat too, done well!

[iht2670]

Very nice never thought of doing it that way.

Steve.

[Trolatron]

Mate thats a brilliant idea , great job.

[Clunk]

Superb idea mate, looks really good

[oncedisturbed]

That looks sweet

[macca]

Very impressive mate, love the bending technique, I'll remember that one...

Looks very neat too, done well!

x2, Clever like it very well done

[mattyh]

I'm amazed by the way you heated it I would never think of that.


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