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Cut rectangular Switch Hole. Anyone?

This is a discussion on Cut rectangular Switch Hole. Anyone? within the Wolverine How To forums, part of the Yamaha Wolverine Gen 1 708 cc SxS category; Very good, looks good as well. Very important having it look good. LOL...

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Thread: Cut rectangular Switch Hole. Anyone?

  1. #11
    Speed Demon
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    Very good, looks good as well. Very important having it look good. LOL
    2017 Wolverine RSPec SE
    Belleville, Ont. Canada

    BigHorn 2.0 27 inch tires
    Half windshield
    Roof
    Aluminum Under armor
    Yamaha Warn 3500lb Winch & Synthetic rope

  2. #12
    Hog Chaser
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    I like the wood or aluminum guide idea, but it may be easier to cut with the vibrating tool used to trim baseboards for installing flooring.
    2019 X2 R-spec SE, Black, Full cab, heater, wiper, tracks, 4500 wireless winch,synthetic

  3. #13
    Hog Chaser BigRed's Avatar
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    cut a couple of more holes. did them both at the same time so i would get them level and square to each other.
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    think i could have gotten two to each side but it would bee getting crammed so i decided one per side will do.
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    don't know what i'll use the other for, maybe rock lights. so just used a cover for now.
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    one left to go for winch.
    Tripplec likes this.
    2019 X2
    oem full windshield
    soft rear window
    KFI stealth 3500 winch
    warn provantage plow
    auxbeam 32" light bar
    Little Trees pine air freshener.

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  5. #14
    Speed Demon
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    You're the man!!! I was never sure all them individual switch, charge port items are the same size. I have been looking at panels with items fitted in them that would have to go in place of the safety plates area.
    2017 Wolverine RSPec SE
    Belleville, Ont. Canada

    BigHorn 2.0 27 inch tires
    Half windshield
    Roof
    Aluminum Under armor
    Yamaha Warn 3500lb Winch & Synthetic rope

  6. #15
    Hog Chaser BigRed's Avatar
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    Quote Originally Posted by Tripplec View Post
    You're the man!!! I was never sure all them individual switch, charge port items are the same size. I have been looking at panels with items fitted in them that would have to go in place of the safety plates area.
    i like the area of the safety stickers for switches but i wanted to hold off on that in case i install a stereo in there. also if you use a plate system you may have to cut a bigger hole. Also wanted LED switch and winch switch away from other switches so i didn't turn off another accidentally.
    2019 X2
    oem full windshield
    soft rear window
    KFI stealth 3500 winch
    warn provantage plow
    auxbeam 32" light bar
    Little Trees pine air freshener.

  7. #16
    Hog Chaser BigRed's Avatar
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    light from top rocker is reflected off of windshield. little annoying but i should be able to fix. don't see it when i turn my roof light on since it is so bright.
    2019 X2
    oem full windshield
    soft rear window
    KFI stealth 3500 winch
    warn provantage plow
    auxbeam 32" light bar
    Little Trees pine air freshener.

  8. #17
    Spectator
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    Ive installed a lot of these switches in my previous life as a car audio installer. The best way i found is to take a razor knife like an olfa or a box cutter.

    Heat the blade with a torch until it is glowing red hot and press it through the plastic. This gives you a nice straight edge.

    Do all four sides and once you have a small hole just keep making it bigger a sliver at a time until your switch fits.

    It takes a bit of time, And stinks but the end result is very clean
    atkbike likes this.

  9. #18
    Speed Demon
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    Well I only installed on toggle switch which is a power master to the panel. The panel blue led's draw 29 mA so I can kill it if I chose. The red lit switch will power the backup lights so I'll know if they're on if I trip it accidentally.

    I cut the hole a bit too wide but manage to get the panel screws to bite into what little plastic was left. Wew...

    I find the owm voltmeter to be off especially when the engine is not running. its about .5VDC low. I wanted a always on 12V socket and also have a phone usb charging pair of outputs None of this draws much current. The lighter socket would be the most when used. I popped the rubber covers so the blue light can be seen.

    I have to work on the rivets from the upper panel which won't drill out. Just spinning right now.
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    2017 Wolverine RSPec SE
    Belleville, Ont. Canada

    BigHorn 2.0 27 inch tires
    Half windshield
    Roof
    Aluminum Under armor
    Yamaha Warn 3500lb Winch & Synthetic rope

  10. #19
    Evil Kenevil erik's Avatar
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    I had a friend try and help me with this... he's normally really good at this kind of thing, but we had a few too many beers, and free handing the dremel worked out very poorly. He felt very badly; consequently he works in a machine shop, so he made me this panel, which in the end worked out better and looks pretty sharp!

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    atkbike likes this.
    2017 Wolverine R-Spec Blue
    2008 B-King
    1997 KLR650

  11. #20
    Speed Demon
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    Looks very good, paid off having them beers.

    LOL

    I looked for months and couldn't settle on a panel. All were too deep top to bottom to fit that upper area which I believe is 3.5" with switches as well as what I have put on. I stayed away from it for future use now. Gauges would be nice for temp and oil pressure. Neither of which are simple to install on this engine. Maybe someone will build a custom kit one day.

    Note the voltage meter in the display reads low when you just turn the ignition on (might does). I could not figure out why my smart charger kept finishing the cycle way to fast and not top the battery all winter. Even the is was used for running lights I upgraded and tested and 5 min runs to heat it up in the winter. That time wouldn't replentish the battery charge used to crank it. I have another source so I'll not need to use that mode on the display.

    Custom panel is sharp!!
    2017 Wolverine RSPec SE
    Belleville, Ont. Canada

    BigHorn 2.0 27 inch tires
    Half windshield
    Roof
    Aluminum Under armor
    Yamaha Warn 3500lb Winch & Synthetic rope

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