Cutting holes in my new dash

[bdbrady]

I am ready to install lighter, hazard switch and glove box lock in my new dash and don't want to screw it up. What is the best method for cutting those holes. There doesn't seem to be any bezels so it seems the fit needs to be tight and smooth. Any suggestions?

[Zs-ondabrain]

Depending on the situation, I would start with a Pilot hole and slowly enlarge to the needed size. Make sure the plastic is up to room temp or even warmer. Cold plastic will crack under pessure. let the bit do the work, don't force it. There is metal behind the plastic and foam so keep that in mind while driving. If the bit starts to wonder when it hits the steel, it'll ruin the plastic.

I like to use a Dremel with a small sanding drum to slowly widen the hole.

[Gary in NJ]

Pilot pilot hole, then a NEW step-bit.

[EScanlon]

If the dash had those items mounted on it previously, why not look at the BACK side of the dash and start with a small "X" cut with an X-Acto knife (not to the limits of the metal). You shouldn't have to cut through any metal.

Then remember that you DO want the bezels to hide the hole, i.e. check the size and placement of the bezels/finishers before you start cutting.

2¢

E

[bdbrady]

Thanks, I'll give it a shot. I looked at the parts car yesterday and identified the bezels for each. The lighter comes apart, the hazard switch has two holes and spins off and the glove gox lock is held in by small tabs which is missing on the new dash as it has never been used. I will pull that off the parts car. Then I''l try the pilot hole dremel solution. By the way I am using your headlight and parking light kits with some H4 lights on this project.