How to make your own switch housings - Part 1

[vonhofej]

Hey guys, This is for all you purist out there. I decided to make my own low profile switch housing out of Lexan (plexiglass) after I got bored with an hour of internet shopping. It slides on to the handle bar and sits just inside the throttle.

Tools and Materials: micro switches (Radio Shack), plexiglass, router table & flush trim bit, mounting tape, drill & bits, jig saw or band saw, cardboard

Steps:
1. Create a cardboard mock up of the switch position (pic 1)
2. Drill a hole to match the diameter of the handle bars in two pieces of plexi (pic 3)
3. Test fit (pic 2)
4. Layout the switches leaving space around the border, identify the area for removal (pic 4)
5. Cut out the first piece. (pic 5)
6. Place mounting tape on the cut piece and fasten it to the second blank (pic 5)
--SAFETY NOTE-- ***When using the router table with these small pieces, use push blocks or fasten them to a larger piece of material. It will try to steal your fingers.***
7. Use a flush trim router bit on a router table to cut the second piece as an exact copy. (pic 6)

 

[vonhofej]

8. Remove and separate the pieces (pic 1)
9. Set the depth to the deepest switch (pic 2)
10. Cut both sides to depth using the router table (see safety note)(pic 3)
11. Mate both pieces and drill holes for the switches. An additional hole was made in the center for a set screw and in the back for the wires (pic 4)
11a. Optional - bevel the edges for more of a pro look
12. Install the switches and attach the wires (pic 5)
13. Paint and mount to the handle bar (unpainted shown, pic 6)

The cool thing is you can modify the design for your application. Mine has an on-off ignition switch on the top and a 3-position switch for the turn signal on the bottom. You could also use push buttons for the horn or other items.

Have fun!

 

[thelowlife]

Cool idea but that thing is HUGE!

 

[vonhofej]

It works good with my huge sausage finger gloves!