Custom Switch

[xintersecty]

A member made a thread about making a switch out of the insert next to the emergency flashers:
http://www.aveoforum.com/forum/f103/...-button-19355/

I wanted to add to that thread and put together a DIY for just a switch. In my case it's a momentary on/off switch for a truck horn.

Materials: JB Weld, wax paper, sander, saw, switch.

I used a switch from ACE hardware.

1) Remove the insert from the center console. You have to remove the assembly from center console. There are three screws holding on the assembly. Once the assembly is removed push on the tabs and it should push forward.

2) Mount the blank cover in a vise for sawing. Cut into round part do not cut the square part otherwise you will remove the plastic holding the tabs.


3) This is the round part cut off. It's time to sand it get clean. Take off about a 1/8th inch.


After sanding


4) Use the sander and clean up the square part.


5) Mix up JB Weld and place epoxy into the square part of the switch. Do the same with the round part. Place face down on WAX paper to make a clean side.

DO NOT USE regular epoxy. I made a mistake here and I got crap for results. I had to redo stuff making it longer. Use JB Weld.


6) Use a Dremel tool with the conical grinder attachment and make a hole in the center. The hole should be big enough for the switch and yet tight enough to hold the threads in place. I almost had to thread mine in place.
7) The switch should fit into the back side of the square part of the blank.
Drill a hole into the button itself. Mount a 1/2 or 5/16 long screw


9) Using a the Dremel make an other hole into the circle part of the blank. This will become the hole.
Here are three parts ready for assembly:


10) Use more JB Weld fill in the hole into the circle part. Use some wood to make an offset and suspend the switch over the circle part.


I will finish up with assembly and labeling on the next posting.

[xintersecty]

11) Clean up the front of the switching using acetone


12) Test the switch before using. My multimeter has an open/short feature. Short means it works.


13) Mount the switch into the bracket. It should slide in from the front.


14) Put the switch holder/assembly back into the center dash bezel and admire that shine.

i will cover up the wiring and labeling on the next posting. Oh you guys must wait for the label.

[xintersecty]

More pictures on wiring

14) I used a two conductor connector (trailer section auto parts store) and wired the switch.


15) Wrap the wiring to the switch in tape to protect the circuit. Sad to say this makes it butt ugly.


16) Use a the plastic wiring tube, feed the wires through the cooling vents and back towards the electrical under the steering. This is pretty much depends on need. You can use any kind of switch you can fit in the plastic blank.


17) Button everything up and enjoy.

[Daox]

Nice job! Looks very OEM.

[petrified.rabbit]

For all that work, I would just bought another hazard switch and painted the button :P

good job for the ingenuity

[xintersecty]

For all that work, I would just bought another hazard switch and painted the button :P

good job for the ingenuity

I actually did that. I bought an hazard switch. I found it it not suitable for application. The hazard switch is a on/off switch with a light. I need a momentary contact switch for a horn. Oh trust me, I am lazy. If there was an off the shelf application, I would have done it.

[camopaint0707]

what I did was relocated the hazard to the left spot, and added a switch to the right spot for fog lights. Both are hazard switches.

[xintersecty]

what I did was relocated the hazard to the left spot, and added a switch to the right spot for fog lights. Both are hazard switches.

Sweet! I thought about doing the fog lights there. I wanted a more factory look, I will not have the factory wiring that goes with it. That was smart move. What did you do for a connector?