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Old 04-28-2003, 01:39 PM   #1
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Lightbulb Analog clock @ center vent panel mod

This is a mod to (eventually) replace the stock lcd clock with an analog clock for better visibility during daytime. In certain times of the day, the contrast between sunlight and shadows can get so high that the lcd clock may be hard to see.

Here's the conceptual sketch. Note that the original rectangular shaped vents in the center console, as well as the hazard switch, has to be moved. In general, other gauges can be placed here too.


Here's the final result (for now).
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Last edited by satrya; 04-28-2003 at 04:40 PM.
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Old 04-28-2003, 01:42 PM   #2
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Lightbulb The clock

I chose to use a 2" VDO clock. This particular unit is an oem part for VW and Audi models, not sure which model though. The dials are supposed to be red and yellow, but in this case, the colors have faded to yellowish white. There are some rust on the bezel. No matter. The bezel & cover will go away for the needle repainting.
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Old 04-28-2003, 01:45 PM   #3
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Open the clock

The clock needs to be pried open for the needle repaint. The bezel can be pried off by slowly working from the side with a thin flat screwdriver or any other similar shaped tool.
Here's the clock after bezel removal. The needles look yellow enough in this photo, but in reality, it's more whitish.
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Old 04-28-2003, 01:47 PM   #4
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Paint the needle

I found an inexpensive yellow paint from a local Home Depot store for $1.88 before tax.
The color is called sun yellow. It looks reasonably close to the unlit color of the oem tach/speedo cluster.
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Old 04-28-2003, 01:49 PM   #5
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default The vent replacement

Since the oem rectangular are spaced too closely from one another, a smaller one needs to be used for replacement. I found a round vent for 2.5" ducting that looks reasonably close to the "eyeball" vents on the sides of the oem GD impreza gauge.
Here's how it looks when the vent is open.
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Old 04-28-2003, 01:51 PM   #6
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Vent DOF (degree of freedom)

Here's another view of the vent, closed. The vent allows for 2 DOFs of rotation.


(Edited for the # of DOF)

Last edited by satrya; 04-29-2003 at 06:44 PM.
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Old 04-28-2003, 01:54 PM   #7
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Exclamation Hazard switch

Next, is the hazard switch. The switch can be easily removed from the original center vent panel. The problem with the original switch is that the switch button is angled; which requires it to be remounted in a panel of similar angle. Aftermarket hazard switches do not necessarily have the same number of connections and harness. I chose to detach the button from the switch instead. Here's how the switch looks without the button.
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Old 04-28-2003, 01:55 PM   #8
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Concept sketch for button replacement

The switch has four wedged tabs to hold the original button. The sketch below illustrates how a new, flat switch can be made by folding a flat sheet of metal, with cut-in shapes for the tabs to latch on to.
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Old 04-28-2003, 01:58 PM   #9
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Front view of replacement button with drilled and countersunk holes.

The hazard switch has a single bulb that lights up when the oem speedo/tach cluster is lighted up. Since this is a good safety feature, the light can be made to shine through by drilling small holes on the custom button. The picture shows 6 holes simulating the triangular hazard symbol.
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Old 04-28-2003, 02:00 PM   #10
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Rear view of the button

Here's the rear view of the button. To make the light more diffuse, a translucent piece of plastic can be placed inside. I chose to use some scrap translucent plastic and color it red (not pictured).
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Old 04-28-2003, 02:02 PM   #11
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Hazard switch placement test.

Here is an early prototype panel made to test the new position of the hazard switch. Note that the holes for the clock gauge and the round vents have not been made. The panel material is an 1/8" thick aluminum sheet metal. Any thinner, and it would be very difficult to drill nice consistent holes using simple tools. Any thicker, and it would be impossible to use scissors to do the cutting. I prefer Aluminum over steel.
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Old 04-28-2003, 02:06 PM   #12
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Updated template (version 1.0)

Using the previous test panel, an updated panel is cut. Note that it may be difficult to make one panel without any modification, since the original panel has many curved surfaces.
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Old 04-28-2003, 02:12 PM   #13
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Ver. 1.0 panel with clock and vents

Here is a test fitment of the VDO clock (cover removed) and the two 2.5" vents. The sides of the panel are cut to be larger than the actual shape. This allows the panel to be bent and rounded on the sides to give it a more solid look (as opposed to being able to see the edge of the panel). Note that the bottom side is recessed a bit. This is the true panel where the hazard switch is mounted on. There will be a cover in front of it.
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Old 04-28-2003, 02:15 PM   #14
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Top view of ver.1.0 panel

The top / back view of the panel shows how the vents and clock are mounted. The vents are a two-piece design, with the outside part threaded into the inside part.
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Old 04-28-2003, 02:17 PM   #15
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Bottom view of ver.1.0 panel

The bottom view shows the recessed mount for the hazard switch. The rectangular hole for the hazard switch is sized just so that the switch will snap on securely. Instead of cutting the hole to the exact size, a smaller rectangular hole is cut, and then the hole is extended by bending the sheet metal using pliers. That way, the edges of the rectangular hole is smooth. Works better for the switch, and less work than cutting the exact size and grinding the edges.
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Old 04-28-2003, 02:20 PM   #16
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Test fit of ver. 1.0 panel

Before making the cover panel for the hazard switch, the panel is test-fitted again. This is a shot of the panel with the clock, vents, and hazard switch attached. Only the hazard switch is wired at this point. Note how the 6 holes light up to represent the triangular hazard icon.
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Old 04-28-2003, 02:27 PM   #17
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Ver. 1.2 panel with hazard cover panel

The panel is adjusted further by bending the edges to fit the dash better. Picture below shows the modified panel with the snap-on hazard cover panel (magenta arrow). Fabricating the hazard cover separately from the general panel has several benefits:
(1) since the hazard switch needs to be snugly mounted, it is easier to trim & bend a hidden panel to fit and not worry about the appearance. Trimming and bending may result in unwanted dents and bends, as can be seen on the lower part of the hidden panel.
(2) the separate panel does not bear any load, hence can be made to look nice by careful bending
(3) the separate panel can be made to make up for the tolerance errors in the general panel in the lower area.
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Old 04-28-2003, 02:28 PM   #18
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Rear view

The rear view below shows how the hazard cover panel mounts to the general panel by 2 simple tabs on the upper part. The hazard cover panel is upside down w.r.t. the general panel in this picture. Notice the half-cylinder shaped "clamp" pointed by the magenta arrow. This is to secure the clock. I initially wanted to fabricate a second half and bolt them together to clam the clock. In the end, I decided to simply wrap the clock and the clamp together with tape.
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Old 04-28-2003, 02:32 PM   #19
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Ver.1.2 panel + hazard panel cover

Here's how the panel looks like.
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Old 04-28-2003, 02:35 PM   #20
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Painted panel

The ver.1.0 panel was tested for a few days, and the unpainted aluminum turned out to give out too much glare at times. Here's the ver.1.2 panel after painted "aluminum" color. It's not as dark as the "brushed metal" color of the oem panel (as can be seen on the cupholder), but it's not that bad. Perhaps I will need to get a darker color in the near future. Note that the hazard cover panel is not attached here.

Last edited by satrya; 04-29-2003 at 06:47 PM.
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Old 04-28-2003, 02:37 PM   #21
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Painted panel with clock and vents

Here's how the panel looks like with the vents, clock, and hazard switch attached.
Again, the cupholder is a bit darker.
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Old 04-28-2003, 02:39 PM   #22
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default The non-matching silver paint

FWIW, here's the silver spray paint I used. If you want to custom paint some items to match the oem color, this is not the right one.
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Old 04-28-2003, 02:41 PM   #23
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Wiring for the clock

I used information from northursalia.com for the wiring information. I tapped from the harness going to the oem stereo.
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Old 04-28-2003, 02:47 PM   #24
satrya
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Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Connectors

Instead of using standard connectors, I decided to use these connectors so that I can easily tap for future wiring of additional electronics.
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Old 04-28-2003, 02:50 PM   #25
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA
797

Default Final result, bright surrounding

Here's how it looks with bright surrounding. I had to take the clock cover off for now; looks like a version 1.5 or 2.0 will need to be made soon for that. Maybe a better matching silver paint too. If anyone knows of a reasonably well matching color, I'd appreciate it if you could share that info.
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