I now have a 100% exact negative of the perimeter of the component I am trying to make an accomodation for in my panel....which in this case....is the Garmin ++...

Once I have that "frame"....I can transfer to whatever I am working on....wood....metal...glass...

Two big pros are....I have the template and can manipulate the position and where and any how....plus....it is a press fit into the finished part with a VERY low profile.....but still has the ability to be serviced and or replaced...

So...now to our resident task....

Mike (I.C.U.) and his upgrade...

Here is the collection along with the original helm panel, and proposed replacement...

Asthetically, my issue with this is the layout and "extrusion" from the panel.

Not baggin Mike....but really no need for an upgrade unless youre gonna
U
P
G
R
A
D
E
Right?

So....where to start....??

We need a "clean" surface...then we can do the layout options..

First pic looks like a big square....but pic two shows the protective (peel coat) removed and you see we are dealing with 1/4" semi-transparent acrylic.

NOT PLEXI-GLAS!!!!!!

Acrylic.

I lay the original on my N E W dash (helm) panel...

Very nice work, you explained the router and jigging process very well.I did a dash upgrade last winter and went through your pain i got a little lazy and got it done w a cnc setup but mine was also 3 sided. I used 1/4 polycarbonate as a backer then bent my wing pieces on a heavy sheet metal brake with adjustable jaws. I also had a duplicate made from a carbon fiber veneer with an adhesive backing. I sheared it into 3 pieces and glued them on. Pm me if you want pics for ideas I noticed there wasn't any talk of what you were gonna make the dash panel out of

Trace it out....use a F A T tipped marker.

I say this so you don't cut your new piece to small. There needs to be a bit of margin for error there.....and if you "cut" the line....you are always "safe"......

Up to you...but here are a few tips....

Use a vari-speed jig-saw
Use it a L O W speed when cuttin acrylic
Use the blade tension at loose while cutting.....

Below, you will find my tried and trued results....without shameless promotion...

When it comes to ANY plastic/acrylic and cutting, heat will ruin your day! Just consider....it is heat that is used to create these products from raw material....

So....while cutting, go slow! Go easy!

How many times have you taken something apart...and put it back together with minimal "force"....only to realize later that it is now PHUCKED?

Slow. Easy. Oh yeah....and slow.

WD-40 helps too! Keeps it slick and cool....ask my wife....

NO...DON'T!!!!!!!

Back to the task....

Now...cut it out ROUGH with the jig saw...no shameless plug intended....but remember to go SLOW....and keep it tight to you line without going inside....

A closer look shows the final prep for the router table...2-sided thin tape from a local supplier (national actually) and the adjustment of the JessEm to the factory (original) panel to the NEW panel

Grrrrr....gettin drunk now...