It all started with a mod idea for N/A 1G DSMs that will allow addition of one extra gauge while keeping the instrument panel looking un-modified (1G gauge cluster setup). Finally was able to gather up all necessary materials to make it happen:
Temporary paper gauge faces will be replaced with factory-style plastic ones after the design is finalized.
The mod requires only basic tools:
Flat screwdriver
Two phillips screwdrivers, one regular, one precision
Sharp knife and/or small saw blade (for trimming plastic)
1/16" and 3/16" drill bit
Drill for said bits (can be hand cranked since it will only be used for drilling plastic)
Soldering iron, flux, and solder
Some spare wire
For this let's start with a Turbo 1G (or an N/A cluster and tach/boost gauge from a turbo) cluster removed from a car. The extra gauge to be put in is a volt meter.
1~ Unbolt all bolts off back side of cluster and remove flexible wiring panel.
2~ Carefully remove clear lense and black trim off the cluster.
3~ Pull out all gauges.
4~ Pop off small "lenses" that cover warning lights on the left and in the center.
5~ Carefully pry off fuel gauge's needle.
6~ Remove two small black screws off front of fuel gauge.
7~ Remove face plate and clear "lens" off fuel gauge.
8~ Repeat steps 6 and 7 on tachometer and boost gauge.
9~ Trim tach's "lens" to accommodate the fuel gauge.
10~ Trim cluster housing so mechanics of fuel gauge can fit where boost gauge usually sits:
11~ Drill a hole in tach's "lens" to allow for the fuel gauge to be bolted up.
(Note where a clear piece was removed to allow the fuel gauge to be mounted)
12~ Attach fuel gauge, tachometer and it's face plate to the "lens". Re-install needles on both gauges.
13~ Re-install the gauge back into cluster housing:
14~ Remove glass off a volt meter by prying/pulling off metal ring that keeps it in place.
15~ Remove face plate and needle, unbolt every fastener off the back.
16~ Remove housing off the volt meter by lightly tapping on connector bolts against a hard surface. Pull off the housing after it comes loose.
17~ Inspect the volt meter and trim off all unnecessary protrusions off it.
18~ Use housing as template and mark necessary holes to be drilled in cluster housing so that voltmeter will fit where fuel gauge was.
19~ Drill the holes.
20~ Determine where holes need to be drilled to install factory "lens" and face to volt meter.
21~ Drill necessary holes.
22~ Attach "lens", face plate, and needle to the gauge.
23~ Mount gauge inside cluster housing.
24~ Re-install other gauges and "lenses" for warning lights.
25~ Re-install the trim piece and "lens" on the cluster.
26~ Rewire the cluster on the back side so that everything is functional.
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Temporary paper gauge faces will be replaced with factory-style plastic ones after the design is finalized.
The mod requires only basic tools:
Flat screwdriver
Two phillips screwdrivers, one regular, one precision
Sharp knife and/or small saw blade (for trimming plastic)
1/16" and 3/16" drill bit
Drill for said bits (can be hand cranked since it will only be used for drilling plastic)
Soldering iron, flux, and solder
Some spare wire
For this let's start with a Turbo 1G (or an N/A cluster and tach/boost gauge from a turbo) cluster removed from a car. The extra gauge to be put in is a volt meter.
1~ Unbolt all bolts off back side of cluster and remove flexible wiring panel.
2~ Carefully remove clear lense and black trim off the cluster.
3~ Pull out all gauges.
4~ Pop off small "lenses" that cover warning lights on the left and in the center.
5~ Carefully pry off fuel gauge's needle.
6~ Remove two small black screws off front of fuel gauge.
7~ Remove face plate and clear "lens" off fuel gauge.
8~ Repeat steps 6 and 7 on tachometer and boost gauge.
9~ Trim tach's "lens" to accommodate the fuel gauge.
10~ Trim cluster housing so mechanics of fuel gauge can fit where boost gauge usually sits:
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11~ Drill a hole in tach's "lens" to allow for the fuel gauge to be bolted up.
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(Note where a clear piece was removed to allow the fuel gauge to be mounted)
12~ Attach fuel gauge, tachometer and it's face plate to the "lens". Re-install needles on both gauges.
13~ Re-install the gauge back into cluster housing:
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You must be logged in to view this image or video.
14~ Remove glass off a volt meter by prying/pulling off metal ring that keeps it in place.
15~ Remove face plate and needle, unbolt every fastener off the back.
16~ Remove housing off the volt meter by lightly tapping on connector bolts against a hard surface. Pull off the housing after it comes loose.
17~ Inspect the volt meter and trim off all unnecessary protrusions off it.
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18~ Use housing as template and mark necessary holes to be drilled in cluster housing so that voltmeter will fit where fuel gauge was.
19~ Drill the holes.
20~ Determine where holes need to be drilled to install factory "lens" and face to volt meter.
21~ Drill necessary holes.
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22~ Attach "lens", face plate, and needle to the gauge.
23~ Mount gauge inside cluster housing.
24~ Re-install other gauges and "lenses" for warning lights.
25~ Re-install the trim piece and "lens" on the cluster.
26~ Rewire the cluster on the back side so that everything is functional.
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