How to install a cool looking power panel in your vehicle

Step 4 Shaping the panel

I used a drill to drill into the painted areas. Use a bit large enough to fit in a jigsaw blade.  Then rough cut the shapes with the jigsaw.  You can finish the shapes with a file so it looks nice. this is where you will be happy you chose aluminum instead of stainless steel.  test fit everything as you go along. File off all the sharp edges as well.  The small slot for the USB was made by drilling a hole at either end and using some small files to shape the slot.  To give it a cool "brushed finish" all you have to do is run the aluminum back and forth in a straight line over some medium grit sandpaper.  I think I use 220.

Comments

[fzxdf5]

a nibbler would have worked great here

[dave spencer]

I have never used one, only seen them on tv. Files are cheap if you are not making a lot of them. I'm not sure I could justify the expense and storage of that tool.

[fzxdf5]

you can pick one up from Home Depot, or simular store or any electical supply house, that is hand operated and is in the $30 range, I think mine is Klien, but it works great and anything you can put into it...stainless is kind of hard upon it

[dave spencer]

hmmm, I might have to go have a look at that. I thought they would be more expensive. thanks for the tip