I just purchase this dash overlay from JBG (http://broncograveyard.com/bronco?search=dash+overlay) to begin designing my custom dash. I had looked at BC Broncos because they sell a complete dash with the Speedo and glove box cutouts already in it, but they are on backorder and I don't care to wait that long.

Few questions:

1. I would love to see some pictures of what people have done with their custom dashes to get some ideas-- so please send some pics!
2. For those that have moved holes, what have you used to cut them? Specifically the speedo guage hole-- I am guessing that a hole saw that big is either unavailable or expensive. Do all of the knobs need a notched hole? Anyone have the hole saw bits they'd let me borrow?
3. How expensive would it be to have someone water jet the cuts needed? Does anyone have somebody in Denver they'd suggest?

Thanks,
Mike

Water jet is usually about 75 to 100$ a hour and I would say it is about a hour job. They are gonna want the cuts in some sort of cad file. If done right it gives a really clean cut and would suggest it especially for rounded holes.
A plasma table would work to.
You could go around to some tech schools and see if they would do it. Quality can be hit and miss with them though.

I've started a dash, but haven't finished it. I'm using 2 large aftermarket gauges, but most the stock switches. I've cut up an old dash and moved the glove box & speaker grill & added a second speaker grill (cut from my current dash- air saw or thin cut off disk).

I had 2 large metal plates cut to fit the gauges and controls. The will be screwed to the dash, for easy access/repair/testing/replacement. I had a metal shop cut the face plates & large circles out. Now that I have a plasma cutter I'd do it myself.

I kept the heater controls where the were, so I wouldn't have to mess with the cable lengths.

I don't have the heater control holes finished, I'll do that when I have the controls out of my dash & can test fit them.

The dash needs some filler & paint, but I want to test fit it all with the new harness before I finish it. But that project keeps getting pushed off.

Thanks Gunni. I've never used a plasma before but Justin has one he is going to let me use to make the large cuts.

Does anyone have any pics of their dash if the moved the speedo gauge to the right of the column? Trying to decide if I should put it right next to the column or center it on the dash. My radio is going in my center console.

With the stock gauges I'd keep it close to the column. You'll have some parallax issues reading the gauges if they are far away.

Even though they can be expensive, hole saws work great for dash work. I bought a few when I made my dash and can say they were well worth it. Plasma can do pretty well, but will take a bit of clean up work unless you can run one extremely well. I thought about using my plasma when I did mine but could not get the super smooth circle out of it so I just hole sawed it.

That's a good point Phil. I'm thinking I might just move it over to the other side of the column.

Crawler, I don't suppose you bought a hole saw large enough to cut the whole for the stock speedo?

I have some pretty large hole saws... What size is it? I've gotten rid of mine long ago so I can't measure.

Damn, the biggest I have is 5.5". Amazon sells them for about $45 if you decide to go that route. Sorry!

We can use a template and the plasma. Won't be quite as perfect, but itll still look good. I've got some sspare sheet metal we can do some test runs on unless someone has one.