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Custom Dash Panel for DR650....sort of.

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TXHillbilly

TXHillbilly

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Jan 20, 2017
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Location
Kerrville, TX
First Name
Jared
I needed a 12v power supply, something to charge my phone with and wanted a voltmeter to monitor it all.

Here are some photos of what I made yesterday. I hope someone finds this useful:

This is my stock layout. Pretty basic.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4393

This is the $11 kit I bought off amazon.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4396

I wanted to make the dash out of aluminum, so first I found this wheel chair foot support in scrap.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4397

Being cast aluminum, it cracked in half before I could finish rough cutting it. Using a giant reciprocating saw was probably not the best tool for the job though. That's okay though because my sketch was off pretty far.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4398

I found the sign and made a better sketch of how I want the layout and began cutting and shaping. Warning: Aluminum transfers heat quickly. Best to wear gloves. Also, safety glasses, ear plugs, yadda yadda yadda.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4394

Using the plastic frame from the kit as a guide, I found a hole-saw that was the perfect size, however I couldn't find the bit part that it attaches too. So I found the perfect size drill bit, but again couldn't find a drill press or chuck big enough to accept it. (I have an odd assortment of tools)
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4399

So, I stepped it up using 3 drill bits.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4392

Then finished it up with a stone bit. Several times I had to take the stone to the bench grinder to get the packed aluminum out of it so it would grind better. Also, at this point if the bit got caught in a bind, there was a risk of bending the panel especially with all the leverage of the drill.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4400

Here it is with holes cut and how I wanted it positioned. Sorry for the upside down upload.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4387

Here is the dash panel completed and wired up. I bent the top portion over 90* to give it some rigidity.
picture.php

http://www.twtex.com/forums/picture.php?albumid=844&pictureid=4391

A similar dash on amazon goes for $54. Probably worth the time to just buy it, but I'm trying to build my bike on the cheap. I made this with $11 in components and scrap material. This shouldn't take but an hour or so to make if you have all the correct tools and material. I did not, so it took about 4 hours. Most of that hunting tools.
 
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It is.

That looks similar to what I did for my DRZ. I made a rough template for mine then decided it was good enough. The fit and finish of yours is much better.

I used the same type gauges and outlets that you did. I have not had any trouble with the standard 12V outlet, but I've gone through no less than 5 of the USB outlets and none of them will work for more than a day or so. I'm anxious to see if yours holds up better.
 
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Crew Chief said:
It is.

That looks similar to what I did for my DRZ. I made a rough template for mine then decided it was good enough. The fit and finish of yours is much better.

I used the same type gauges and outlets that you did. I have not had any trouble with the standard 12V outlet, but I've gone through no less than 5 of the USB outlets and none of them will work for more than a day or so. I'm anxious to see if yours holds up better.
Click to expand...

Good to know. I actually haven't used the USB yet. I forgot to mention I wanted the voltmeter because I was having intermittent headlight dimming issues and I was worried it was charging system related. Like a dummy I installed it directly to the battery first, then realized I needed key on power. When I was there I found the ground terminal not even finger tight on the battery. Also the wrong bolts were installed in the battery hold down bracket, so they would bottom out before getting tight. All is better now. No more headlight issues. I also forgot to mention I installed an LED bulb last night to free up amperage for accessories. Extra brightness is a nice side affect. :sun:
 
I can still see them. I'm on a computer. I just checked and I can see them with Tapatalk too.

I install a voltmeter on all of my bikes now. I really don't like it when I can't see what's going on with the electrical system. I think you'll like the LED light. I installed on the DRZ and think it's one of the better mods I did. Much better than stock.

Personally I kinda like it when someone can use a little ingenuity and do something. Saving a buck and developing skills are both worthwhile things to do.
 
Ok good. I don't know anything about tapatalk, but maybe it needs to be refreshed or something. I had the photos linked to my album that was set on private at first.

Crew Cheif, having that voltmeter really does set my mind at ease. I hope to install an oil pressure or temp gauge soon. Tonight will be my first experience with the led bulb. I can't wait to see the difference.

Thanks for the kind words about the dash.
 
TXHillbilly said:
Being cast aluminum ....

<snip some really good detail>

I bent the top portion over 90* to give it some rigidity.
Click to expand...

How did you bend it 90* without it breaking, cracking, showing stretch marks, etc.

Just the two mounting points?
Vibration a problem?
 
mitchntx said:
How did you bend it 90* without it breaking, cracking, showing stretch marks, etc.

Just the two mounting points?
Vibration a problem?
Click to expand...

I clamped it in the vise, used a block of wood and a hammer and slowly beat it over evenly. It did stress crack some. Any more than 90 degrees and it probably would've probably snapped. The bottom right angle was also a bend, but it cracked a little more, so I just cut it off. It seems to be very stable.

I recently got a new Tig welder at work. Once I teach myself how to use it, Ill add a support rib if needed. So far so good though.
 
Here is a close up of the bend. I ran it across the bench grinder lightly. Not really sure why I did that. Maybe hoping the stress cracks would go away...haha.

picture.php
 
Working on mine too. Used steel framing plate. Here is pic of first fitting. Am trimming it down some more and painting with bedliner once done. Don't have the cool front flap/bend like yours.
The switches:
Left - Heated Grips,
Center - Voltmeter (may replace with combo Voltmeter/Usb)
Right - Aux lights (future mod)
Green Led's - was going to be power-on indicators for switches, but am considering turn signal indicators to help me to remember to turn them off - lol

997c3e06c69865b2797a03ac9bfe1c0d.jpg
 
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