Mazda FD RX7 Cluster With Speedhut Gauges

This is my first FD cluster I have done. A FD cluster is different from most clusters since each gauge has its own opening in the facia. All of the other clusters I have done have one large lens that the gauges sit behind. Keep in mind that I use the term “gauges” loosely. OEM gauges are not like aftermarket gauges where each is in its own separate chassis. OEM gauges are simply just the faces(dial) and needles(pointer) slapped onto one large plastic housing with the electronics/mechanics underneath the faces. Then typically a black facia over the front of the dials to divide them and make them look like separate gauges. Then of course the clear lens over the front. So the unique design of the FD cluster allows for more of a “drop in” of aftermarket gauges. The OEM sizes are somewhat close to the size of aftermarket gauges, but not near exact enough for me. Unfortunately this customer sent me a carbon fiber facia, so I couldn’t really modify it to fit the gauges how I would have preferred. Ideally I would fill or enlarge the OEM gauge openings to fit the aftermarket gauges exactly. I would then re-texture the whole facia and give it back the OEM look/finish. I just finished another FD cluster where I did exactly this… so stay tuned for that post. In the meantime, enjoy some images from this carbon fiber facia cluster.

S14 Cluster Build

Just another S14 cluster build… well, not so fast. This just isn’t any old customer. It’s Peter Tarach, editor in chief of Modified Magazine. Peter and I have known each other for several years now. I help him, he helps me… it’s a good relationship! So naturally when he asked about a cluster for his track S14 I was more than happy to oblige. However, this cluster wasn’t just going in the car, it was going to have its own little write-up in an issue of Modified Magazine. Now as I typed this a few months back, it appeared that Modified Magazine was going to be closing their doors… and they did. I’m not sure what that means for getting this cluster featured in maybe whatever magazine Peter works for next, but that’s not what it’s all about. It’s not even about the money. It’s about seeing how satisfied people are when they receive one of my products. It’s an honor for me to have one of my clusters or interior pieces residing in a customer’s dashboard. Whether they are a well known drifter, a 16-year old kid with his very first ride or in this case, Peter Tarach. So I wish the best of luck to Peter and his new ventures… along with the rest of the staff at Modified Magazine.

I guess it’s time to get down to business. The first thing I ask any potential cluster customer is what they want in it. I have to make sure everything is going to fit comfortably. I refuse to cram things in. It has to look natural with an adequate amount of spacing between gauges. In this case Peter already had a Stack race display that he wanted retrofitted into the cluster. “Cool” I said, those things are sick and have an ultra-clean style to them. He also wanted his 45mm Omori boost gauge and 52mm AEM wideband mounted in there. Naturally this threw up a red flag for me. Not only were the gauges different brands, but they were different sizes. This really “gets my goat”. So I politely suggested to him that we ditch those two gauges and replace them with a couple Speedhut gauges. After all, this is going to be in Modified Magazine. I can’t have a mish mosh of equipment floating around in there, LOL. I suggested Speedhut for a couple reasons. For one, I’m a Speedhut dealer and am very familiar with them. I could just order them up and he would not need to worry about it. I wanted to make it as easy as possible for him since I just told the guy that I didn’t really want to use the gauges he just sent me. Second of all, Speedhut gauges are completely customizable. Which meant I could match the look and illumination of the Stack display. Peter, being the good guy that he is, agreed to all of this. Not to mention that Speedhut was kind enough to hook us up on the gauges in exchange for the obvious exposure they would receive in the magazine article. Now that we were set on the equipment, it was up to me to make it all come together inside of an S14 cluster.

In case you didn’t already know, I prefer to retrofit the aftermarket equipment into the OEM cluster housing. It ensures that the cluster will simply bolt back into the dashboard just like it came out. But most importantly, it maintains a nice OEM style with the flair of the aftermarket equipment inside of it. I also try to reuse the OEM cluster lens… I think it helps finish off the look. I offer an optional 7-step polishing process to restore the lens back to new. So first thing is to gut the OEM cluster housing. This is the cluster in stock form:

OEM lens removed. As you can see it’s in need of some love:

OEM cluster surround removed. This piece will need to get trimmed/gutted to perfection in order for this to all come together… more on that later:

Back half of the OEM cluster that houses the actual gauge faces, electronics and circuitry on the back:

Everything removed from the back half:

Now that disassembly is complete, it’s time to start modifying everything in order to accept the new gauge plate. I use a 3/4″ piece of MDF for the plate. This allows me plenty of thickness to flush the gauges… which I feel gives a much more finished look over simply surface mounting them. The OEM cluster surround needs to be opened up to remove the horizontal flat section where the OEM gauge faces use to reside. This means grinding/sanding perfectly right up the surround wall. It also needs to be perfect on the backside so the new gauge plate butts right up against it without any gaps or weird undulations.

My tool of choice when modify virtually any plastic is a die-grinder. I use a burr type bit to rough cut the majority of the plastic away:

Next I use a 1-1/2″ drum sander on the die-grinder to rough sand it down to match the exact contour of the interior wall of the cluster surround:

Close-up of the precision sanding:

Next up is to modify the back half of the cluster. Not only will this allow the new aftermarket gauges to physically fit, but it also serves to “sandwich” the new gauge plate between it and the front cluster surround. First thing is to grind all of the nubs and high spots off the back of it:

Grinding off the extra plastic on the back allows me to easily run it through my scroll saw. The saw is used to rough-cut away the horizontal flat section… thus leaving just the wall:

Next I use the same drum sander used earlier to finish off the rough spots. It doesn’t have to be perfect since it will never be seen, but there’s no need for it to look like a hack-job:

As discussed earlier, I use a 3/4″ thick piece of MDF for the main gauge plate:

It butts up against the back of the surround nice and flat since I took the time to make sure the surround was sanded carefully and true:

As seen in the image below, the 3/4″ thick gauge plate is far too thick for the back half of the cluster to snap back on. So I simply use a router to make a rabbet cut around the perimeter of the plate:

With the rear half of the cluster modified, it’s time to move on to the main plate. The Stack display is installer friendly in that it has a thin lip all the way around the perimeter for it to surface mount into a plate. However, I wanted to go one step further and flush mount it into the new gauge plate. First thing is getting it marked out. As you can see in the image below, I got lucky that it barely fits height wise within the S14 cluster surround:

The inner line gets cut out with a jig saw, then the flush portion is created again with a rabbet bit. However, the lower corners are too tight to use the rabbet bit. So I hand carved/shaped the flushed ledge in those areas:

As mentioned earlier, we agreed on the 52mm Speedhut Revolution series gauges to flank each side of the Stack display:

Also added in flush turn signal indicators and eventually a Stack shift light off to the right side:

I’m constantly test fitting things as I go… this is one of those times:

This after an initial coat of SEM Satin Black Chip Guard. It typically takes several coats to get a texture I’m satisfied with. I love this stuff!

After six coats and some dry time, I test fit everything to make sure I’m still on track:

Last thing on the list, before I can call this complete, is to polish the OEM lens. I start off with wet sanding the inside and outside with 1200, 1500 then finish with 2000 grit. I then polish the inside and outside with four stages of polish. This is after the wet sanding to get all of the deeper scratches out:

The finished product ready for service!

S13 JDM Window Switch Assemblies Retrofitted Into S13 USDM Window Switch Plates.

Well, this job was slightly unexpected for me. Don’t get me wrong, it’s right up my alley. However, the cost for me to do something this tedious is not cheap… and for what most onlookers would refer to as a waste of money. With that being said, I completely understand the customer’s reasoning. Hell, I do the same sort of thing all the time… spend tons of money or time on things that will go unnoticed by most.

So down to it! This customer had a set of S13 JDM window switch plates/switches that he wanted in his S13 USDM vehicle. Seems easy enough, just unsnap/unscrew the switch assemblies from the back of the JDM plates and attach them to the back of the USDM plates. WRONG! The switch assemblies are of completely different design from the JDM to the USDM version. Not only that, the window switch plates have the opposite curve to them since the plates are obviously on opposite sides of the car in JDM land. If you take a look at the images below, comparing the JDM and USDM, it quickly becomes apparent the differences. The switches themselves are also different. The USDM switches(not pictured)are a simple push forward and push back. Whereas the JDM switches are a pull up and a push down style. Which means there also needs to be a “cup’ formed in the plastic in front of the switch. That way your finger doesn’t just poke through when you are trying to pull up on the switch. In the following images, the USDM plates are the ones without the actual switches in them.

So the only way to properly do this was to cut out the section that has the JDM button openings, thus retaining the original JDM button mounting setup on the back. Then hack out a similar size opening in the USDM plates and retrofit the JDM assemblies into them:

The cut out JDM assembly on the right needing to go into the USDM plate on the left:

USDM plate ready for the transplant:

Test fit to make sure I am still on course:

Same with the passenger side:

Next it was time to bond these permanently into place with one of my favorite products… Norton Speed Grip 2-part adhesive. Note: just to get setup with this stuff it will cost a minimum of $100. The glue is very expensive and it takes a special applicator gun to apply it. But it’s so worth it if you need to bond plastic.

At this point it’s time to get it looking good. A lot of rough sanding, shaping, forming, a tad bit of Evercoat Fiber Tech filler, some primer and here you go. Well, some of those steps need to be done numerous times!

My customer also requested a white LED to be mounted in the driver side switch:

Last but not least, some SEM Satin Black Color Coat:

S14 HVAC Panel With AEM 52mm Gauges Angled.

This seems to be the most popular piece that I duplicate:

Finished Up Some Custom Nissan Pieces

The first one is the driver’s door handle/vent trim from an S14. The customer felt that a boost gauge was more important than a door vent… I can’t say I disagree with him:

Next up for another S14, flush mounted Speedhut gauges in place of the HVAC controller:

My true love, S13 goodness. Again, three Speedhut gauges flush mounted in place of the HVAC controller:

Another S13 utilizing some risky gold bezel Speedhut gauges… I love the outcome!

Got Clusters!?!

Finished up a batch of clusters recently.  Business seems to be picking up with the release of my new website, Facebook page and the sponsorship I was offering for a short spell.

 

Nissan S14 cluster utilizing a Stack Cluster flanked by 2-1/16″ Speedhut Revolution series gauges with optional 7-step OEM lens polishing:

 

Nissan S13 cluster housing an array of Defi BF gauges with OEM lens delete:

 

1998 Honda Civic cluster utilizing a 4″ Speedhut Revolution series GPS speedo dual gauge flanked by 2-5/8″ Speedhut Revolution series gauges with optional 7-step lens polising:

 

Mazda FC RX-7 cluster housing (2) 4″ Speedhut gauges and AEM boost gauge:

 

Nissan S14 cluster using an array of Speedhut gauges… (2) 3-3/8″ and (2) 2-1/16″, also 7-step OEM lens polishing:

 

Nissan S13 cluster utilizing an assortment of Speedhut gauges, optional LED turn signal indicators and optional 7-step OEM lens polishing:

 

Nissan S14 cluster using (2) 3-3/8″ Speedhut gauges and (2) 52mm AEM gauges:

Overall Update

First off I am still alive… and yes, I still have the S13. I will be posting various updates in the next few days covering customer projects, my car and whatever else I feel is important enough to talk about. I haven’t really touched the car this year because I’ve been trying to heavily promote my Broadfield Customs business. I released my first website a couple of months ago. It’s my first attempt at a website… and while pretty basic so far, I’m fairly pleased with it. One of the main reasons for the site was to better explain the process of the work I do. I kept getting the same questions over-and-over and/or there was a lot of confusion on the process of having me fabricate a custom interior piece. So the website gives me a place to direct potential customers and also hopefully gain new customers through searches engines etc. Please take a look around and see what you think:

Broadfield Customs Website

Likewise, what is social media without a Facebook account!?! So I have also been trying to get the word out on Broadfield Customs Facebook. Please take a gander and like my page. You can also friend me on my personal Facebook at Toby Broadfield’s Facebook.

Stay tuned!

Customer’s S14 HVAC Panel With ARK Designs Products

I want to apologize for not posting in quite some time. I have been busy with anything and everything that doesn’t involve working on my car. So thanks to those that still follow the blog. I finished up some fabrication for a customer over seas. It was my first time working with any of the ARK Designs products… they are pretty cool and have styling unlike anything else out there at the moment. So I removed the vents from the upper section of he HVAC panel and cut the center pillar out. I then adhered a backing plate that would be the home for the ARK products. I molded the plate into the surrounding opening of the HVAC panel to make it look like it belonged there. Once I had the contours correct and to my liking, I cut out the openings for the ARK pieces. This is always time-consuming because it needs to be almost perfect. I always rough cut with a die grinder to get it close then I use a combination of various files and various sandpaper grits to get them spot on. After that some texture coating and mounting the units in place. I only took a couple of progress pics as it really slows me down during the fabrication process:

Some final test fit action:

Finished product: