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Old 03-23-2006, 10:18 PM
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Aluminum Bezel DIY by mdk5623

Wiggled out the old cahones (sp?) this evening, (I don't bring 'em out much these days... ) along with the dremel, equipped with the fiberglass cutting disk. Using my best guestimation, I marked two lines with a sharpie on the bottom side of the cluster, (the side that sits on the dash edge) to use as a reference while cutting with the dremel. The first mark I made was on the far right side of the cluster, then made another mark about 7 inches to the left. Using the dremel, I cut from right to left, starting on that right corner. When cutting through this plastic, be careful to not let the inertia of the cutting disk get out of your control--if it gyrates away from you, it will oscillate and scar the inside of the plexi, inside the cluster. If you can find a position that garners you max leverage over the dremel, the cut will be fairly simple--just follow the indented channel that runs the length of the cluster. This plastic will melt within a second of contact with the disk, so be sure to wear eye protection and do this in a well ventilated room. Also make sure and anchor the cluster so it doesn't move during the cut. The finished butchering will leave you exasperated, but if you've gotten this far, you are almost home free. Use a fine exacto blade to widen the channel you've just cut--remove all the burrs and uneven edges as best you can, then test fit the bezel by sliding it up into the cluster through the new cut. I had to widen my channel a number of times--CLUE: Cut the channel longer than you think you need--It wont be seen and is sealed later--then vacuum the crap that shot into the inside of the cluster during the cutting--be careful not to scratch the inside when you are doing the clean up. Once clean, cut the double-stick tape that was included with the bezel and attach it as directed--remove the second layer and then slide the bezel in the slot and pull it through with your fingers through to the inside of the cluster. Push it to the top, check alignment and stick away. Once sufficiently stuck down, check the plexi for prints/debris, then reassemble the cluster. Don't forget to reinstall the odometer 'Plunger' (the black plunger looking rod that is in the cluster and probably fell out when you first opened it..) then you are ready to close it up. Align all your X's and push the cluster closed until the clicks are heard. That's it. Fini!
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