The Ford Barn

Firechickenzz · 08-04-2025, 08:14 AM

Thought I would share what I worked on this weekend.

On my original light switch the internal brass contacts broke, I tried to rebuild them but anytime you went over a bump the lights would flicker. Since the cheapest original replacement I have ever seen was $400 I decided to replace it with a high current push/pull switch off Amazon.

The trick was adapting the new switch to the existing hole in the dash. I thought this would be a good opportunity to use the 3D printer. 15 minutes to design in Fusion 360 and 20 minutes to print I had a new bezel and nut. I settled on the 4th version. Sprayed it with some Chrome Rustoleum, I think it turned out pretty good.

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Kube · 08-04-2025, 09:33 AM

Hum. Just sold a NOS switch two weeks ago. $75

petehoovie · 08-04-2025, 10:55 AM

[QUOTE=Firechickenzz;2404208]Thought I would share what I worked on this weekend.

On my original light switch the internal brass contacts broke, I tried to rebuild them but anytime you went over a bump the lights would flicker. Since the cheapest original replacement I have ever seen was $400 I decided to replace it with a high current push/pull switch off Amazon.

The trick was adapting the new switch to the existing hole in the dash. I thought this would be a good opportunity to use the 3D printer. 15 minutes to design in Fusion 360 and 20 minutes to print I had a new bezel and nut. I settled on the 4th version. Sprayed it with some Chrome Rustoleum, I think it turned out pretty good.

cas3 · 08-04-2025, 01:39 PM

I'm the guy who would be some day be welding that hole shut and cursing the guy for not just fixing the original switch. Originals are still at swap meets for 10 bucks or less

Firechickenzz · 08-05-2025, 08:02 AM

Quote:

Originally Posted by cas3

I'm the guy who would be some day be welding that hole shut and cursing the guy for not just fixing the original switch. Originals are still at swap meets for 10 bucks or less

Its not a new hole. Its just an adapter to the original switch location. I can set it back to stock in 5 minutes. Once I find an original it will be set back. Until then I have dash lights that work.

I would love to find a swap meet that isn't 95% small block related. Next time you find one for $10 let me know.

Zeke3 · 08-05-2025, 10:18 AM

Sponsored Links (Register now to hide all advertisements)

I admire your ability to design and produce an adapter to mount the new switch without modifying the original panel.

08-04-2025, 08:14 AM	#1
Firechickenzz Member Join Date: Jun 2023 Location: Elgin, IL Posts: 69	Dash Lights switch replacement. Thought I would share what I worked on this weekend. On my original light switch the internal brass contacts broke, I tried to rebuild them but anytime you went over a bump the lights would flicker. Since the cheapest original replacement I have ever seen was $400 I decided to replace it with a high current push/pull switch off Amazon. The trick was adapting the new switch to the existing hole in the dash. I thought this would be a good opportunity to use the 3D printer. 15 minutes to design in Fusion 360 and 20 minutes to print I had a new bezel and nut. I settled on the 4th version. Sprayed it with some Chrome Rustoleum, I think it turned out pretty good. 20250802_142552.jpg 20250802_142558.jpg Screenshot_20250803_150058_Gallery.jpg

08-04-2025, 09:33 AM	#2
Kube Senior Member Join Date: May 2010 Location: Wisconsin, USA Posts: 9,853	Re: Dash Lights switch replacement. Hum. Just sold a NOS switch two weeks ago. $75 __________________ "I can explain it for you. However, I can't understand it for you".

08-04-2025, 10:55 AM	#3
petehoovie Senior Member Join Date: May 2015 Posts: 10,158	Re: Dash Lights switch replacement. [QUOTE=Firechickenzz;2404208]Thought I would share what I worked on this weekend. On my original light switch the internal brass contacts broke, I tried to rebuild them but anytime you went over a bump the lights would flicker. Since the cheapest original replacement I have ever seen was $400 I decided to replace it with a high current push/pull switch off Amazon. The trick was adapting the new switch to the existing hole in the dash. I thought this would be a good opportunity to use the 3D printer. 15 minutes to design in Fusion 360 and 20 minutes to print I had a new bezel and nut. I settled on the 4th version. Sprayed it with some Chrome Rustoleum, I think it turned out pretty good.

08-04-2025, 01:39 PM	#4
cas3 Senior Member Join Date: Jan 2011 Location: Beverly Kansas Posts: 5,301	Re: Dash Lights switch replacement. I'm the guy who would be some day be welding that hole shut and cursing the guy for not just fixing the original switch. Originals are still at swap meets for 10 bucks or less

08-05-2025, 10:18 AM	#6
Zeke3 Senior Member Join Date: Dec 2014 Location: Columbus, IN Posts: 1,592	Re: Dash Lights switch replacement. Sponsored Links (Register now to hide all advertisements) I admire your ability to design and produce an adapter to mount the new switch without modifying the original panel.