Custom Switch Panel for a Tacoma

September 26, 2014 12:01 PM

I am adding some accessory circuits to my Tacoma, for things like the Winch, air compressor, and extra lighting and I need to mount the switches somewhere.

There was a guy who was making these console switch panels. I should have bought one then, but I didn't and now he isn't making them - he's been deployed. He also hasn't responded to my PMs asking for info.

I've done a very little bit fiberglass work in the past and am totally willing to learn more. I've kicked around on the intarwebs, but there is a dizzying array of products and types and this that and the other - I have no idea where to even start.

So, I come to the hive mind. I've got a spare overhead console and the switch mount plate. What fiberglass/epoxy products do I need to make it look (really close to factory) like he did ?

posted by Pogo_Fuzzybutt to Sports, Hobbies, & Recreation (6 answers total)

Gosh, I feel like you'd be better served on the Tacoma forums than you would here. That just feels a bit too specific for AskMe.
posted by leotrotsky at 1:53 PM on September 26, 2014 [2 favorites]

Gosh, I feel like you'd be better served on the Tacoma forums than you would here. That just feels a bit too specific for AskMe.

I agree, with the addition of non-brand-specific forums like Pirate4x4 and Expedition Portal.
posted by Dip Flash at 2:09 PM on September 26, 2014

Response by poster: Yeah, I've bothered all of them. Gotten some OK answers, but I don't know a whole lot about fiberglass and epoxy work. Before I drop 100+ bucks on materials, I wanted a better sense of what whether I've gotten good advice.

To be clear, the wiring and all that is easy peasy. Already got that 3/4 done. I just need to know how to do the plastic work on the console.
posted by Pogo_Fuzzybutt at 2:56 PM on September 26, 2014

I think your next best bet would be to find a switch panel that you think could look cool in your vehicle somewhere. Jeep mod forums might be a larger source of inspirational photographs. Good luck!
posted by oceanjesse at 5:19 PM on September 26, 2014

Best answer: I would:

1. Cut a piece of EPS board (IE: rigid blue insulation board) to slightly larger than what you want for your switch mount.
2. Shape the foam to the desired shape with knives/files/rasps/sureform/sandpaper.
3. Apply a smooth surface with something like an autobody glazing putty.
4. Sand to desired smoothness.
5. Pull a mold with RTV.
6. And then cast the part with something like West 105 epoxy, 205 hardener, and thickened with Colloidal Silica.

If you want a hollow piece you can either rotocast the mold you have by hand or layup a layer of cloth in the mold. Depending on the depth you might need a rigid mother mold over your RTV mold to retain the shape.

Once you have the switch holder you can cut your console to accept it and then use more thickened epoxy to retain it in the console.
posted by Mitheral at 6:04 PM on September 26, 2014 [2 favorites]

Response by poster: Sweet. That's largely what I was after.

Like I said, I have the switch plate, and a spare console, so I'll see what I can work out.

Thanks!
posted by Pogo_Fuzzybutt at 2:39 PM on September 29, 2014