I decided to add 4 gauges to my 2006 B-series. oil pressure, fuel pressure, vacuum and voltage.
I bought some spare parts (2 drivers side a-pillars), and I went to a local junk-yard to see what I could do in terms of replacing the lower center dash insert. From the factory this came with an ashtray, and the "airbag deactivation switch" for the passenger side. I don't ever have passengers, and I could care less if this feature works or not. (I'm actually considering removing the airbag all together- but that's a different story.) I also don't need an ashtray (don't smoke). I brought home some similar panels from junk trucks.
I took a pod from another car, did some cutting and modifying and taped it on a factory a-pillar
trying to get a good alignment
once I was happy with the aim, I glued them down temporarily
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next, I wanted to replace my ashtray and airbag switch with gauges. I needed to modify the circuit so the RCM wouldn't disable the airbag system with the switch removed.
Here is the center portion for under the dash. I was replacing the airbag switch, so I needed to reverse engineer the way the RCM interprets the switch, and feed it a signal it was happy with. After looking at the tech schematic and taking some measurements, I went with 2 1000 ohm resistors. I wired them into the hard-shell so I could fool the RCM into thinking the switch was still there.
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I then started the fiberglass process. First felt to give it shape, then fiberglass for strength..
Lots of sanding and body work here....
more sanding and cutting
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Next, after it was pretty smooth, I started with Bondo filler, and then I moved to the super smooth dolphin glaze filler....
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Next I took a brake to set up my sending units. I used a simple 90 degree street elbow to attach into the block and set it up so I could run both the factory oil pressure switch, and a 1/8ntp pressure transducer.
next, I had to modify the fuel rail so I could get fuel pressure. I grabbed some of the end-caps from similar 4.0L fuel rails at my local junk yard. These are some sort of brass/bronze material with a plating. I used my tig welder to braze a nut on the end so I could read fuel pressure at the fuel rail. I replaced the factory shrader fitting.
my first few attempts were really bad!
I ended up taking a slightly different route...
I tested the fitting at 110 PSI in a bucket of water- I originally had a small pinhole leak, but I fixed it. I then installed the vacuum sensor (sorry no picture)
I then went back to doing the body stuff. I used a 2K urethane based activated primer. Several coats, sanding between each.
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Then I used a SEM texture spray on the a-pillar, and a dupont vinyl matching OEM finish paint.
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I painted the center lower dash piece with chromabase OEM exterial metallic (dark shadow grey) and then USC "glamour" urethane clear....
The small hole on the pod was so I could access the screw hole (you can't really see it when installed) I put a pvc pipe there as a guide when I'm screwing it down.
Had to cut a hole and use a grommet to route the wires. (I have so many wires coming in now)
Final results. I think the white LEDs match my re-designed LED cluster that I did in 2014. Everything is white with red needles.