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.