Rally Dash Bezel Drilling Process

[Plymouth Pete]

I purchased a new PG rally bezel through Classic Industries around Christmas. Opened the package and thought it looked very nice. I just finished rebuilding all the gauges and tach and updating to an external voltage limiter. I now was starting to assemble all the parts when I realized that there is no cigarette lighter hole in the bezel. I called Classic to find out the deal. They checked existing current stock and they confirmed no hole. I did a little research and found the best way to make a hole would be with a step bit. The back side of the bezel does have a raised boss for the hole like my original. I then carefully measured my original and copied center onto the new piece. I clamped the bezel with stacks of foam supplied as packing to a table. I first drilled very small pilot hole until it was large enough for the first bit step. I slowly drilled and after each step I checked the measurement with my micrometer. The step bit can be steered somewhat with pressure to keep yourself aligned. The final step is 7/8ths which is just enough room for the lighter. Not as scary as I thought it would be drilling into expensive plastic.

 

[340wedge]

I purchased a new PG rally bezel through Classic Industries around Christmas. Opened the package and thought it looked very nice. I just finished rebuilding all the gauges and tach and updating to an external voltage limiter. I now was starting to assemble all the parts when I realized that there is no cigarette lighter hole in the bezel. I called Classic to find out the deal. They checked existing current stock and they confirmed no hole. I did a little research and found the best way to make a hole would be with a step bit. The back side of the bezel does have a raised boss for the hole like my original. I then carefully measured my original and copied center onto the new piece. I clamped the bezel with stacks of foam supplied as packing to a table. I first drilled very small pilot hole until it was large enough for the first bit step. I slowly drilled and after each step I checked the measurement with my micrometer. The step bit can be steered somewhat with pressure to keep yourself aligned. The final step is 7/8ths which is just enough room for the lighter. Not as scary as I thought it would be drilling into expensive plastic.View attachment 1715075311 View attachment 1715075312

View attachment 1715075314

View attachment 1715075315

Nice Job! I know I had to drill the trip odometer knob hole, and it is just a small hole, but it is unnerving on such an expensive piece of plastic!

 

[RedFish]

Its not there because most owners do not want that lighter well. The odd ball 68 dash ash tray was the only reason a lighter was placed up there in the plastic bezel ( where a hot lighter would melt circles around the hole ). All but 68 model have a lighter in the dash ash tray where it belongs. A large percentage have another lighter location in their console ash tray. Once in a while the aftermarket gets it right.

 

[Plymouth Pete]

Its not there because most owners do not want that lighter well. The odd ball 68 dash ash tray was the only reason a lighter was placed up there in the plastic bezel ( where a hot lighter would melt circles around the hole ). All but 68 model have a lighter in the dash ash tray where it belongs. A large percentage have another lighter location in their console ash tray. Once in a while the aftermarket gets it right.

Thank you for what now sounds logical. I have only owned 68 models.