The next challenge is to mount the minimal necessary instruments on the dashboard in order to provide visibility of the various system parameters to the driver, such as battery state-of-charge, used power or regen from the Curtis motor controller. I decided to use the minimalistic Curtis model 840 gauge, with a toggle switch to navigate through the different parameters. Also, I wanted to include the emergency cut-off button into the same instrument cluster.
Of course it would have been easy to just cut a hole into the existing dashboard and include the additional instruments there. But I didn’t want to modify the original car at all. There was just one existing screw on the very bottom of the dashboard, where the only supporting bracket was attached. So I decided to use that same screw to support an additional little instrument cluster which would hold the electric instruments. This would follow the reversible approach as I could remove the whole instrument cluster with a single screw without leaving any trace.
So here’s how I started off designing the instrument cluster on CAD:
And here’s the finished CAD file for the cluster:
I printed the cluster off in paper to see if everything fits.
Here’s the whole assembly with the paper print, all instruments fitted. Looking good!
Again, the CAD file was sent to my friend’s waterjet cutting shop, and here’s how it came back by post:
And finally this is the whole instrument cluster in the car. It all holds with one single screw and is fully reversible. It doesn’t look intrusive at all in my eyes, pretty pleased with how it came out!
