Carbon Fiber Switch bank for Lights and Accessories on my Pathfinder

Finished (but not cleaned) Carbon Fiber Switch Bank
Here is the Finished switch bank.
Click image to enlarge

I've used this area in my pathfinder for a few different things over the years. For a while it held a CD changer control, at another time it had a single switch in the stock plastic piece, and the switch was for my RF modulator. It is time for something new, and to consolidate the switches that are around the trucks front dash.

The new switch bank will control:

  • Stock Fog Lights (independent of headlights)
  • New Driving Lights mounted on safari bar (not yet installed)
  • Backup Lights on Hitch
  • Hardwired RF Modulator for Ipod hookup to Radio
  • Air Compressor for Air bags in rear suspension

I selected a toggle switch that was easy to use (when fumbling for in the dark while driving, trying to turn on lights etc.), and kind of reminded me of the toggles you see in NASCAR when they say "gentleman start your engines!." They have LEDs on the tips, and based on their action, I picked 4 Reds and 1 Green. It will help to isolate them a little more in the dark. The switches went for $7 a piece.

Carbon Fiber Panel - Well, this isn't really carbon fiber. It is actually KYDEX - a thermoplastic that is pretty tough. This one has a patern on it, meant to look like Carbon Fiber (called Conceal-X). It is less than .1 " in thickness.

The only other components for the project were Wire, connectors, a piece of Aluminum, and some screws for mounting.

Tracing Carbon Fiber for Switch Bank
Tracing the old interior piece, to get the right shape for the new panel.
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In order to protect the Conceal-X I put blue painters tape on it, even though it also has some clear plastic over it for protection. I've found it's pretty easy to scratch it with a drill or something, and have to start over with the piece. The Blue tape was also handy for drawing my marks on for cutting, and drilling while working the piece.

Test Fitting the Carbon FIber panel
After sanding the contours, it fits in perfectly. I've put blue painting tape on there for protection.
Click image to enlarge

After I cut it out (on the bandsaw), I took the piece over to the tabletop sander, and sanded all the edges down to the marks, and made sure that they were strait. Through a number of successive fittings, I worked on getting the piece to fit perfectly with just a little tension in the larger dash piece.

Notch for support
I created a notch under the snap mount for my aluminum support to go through, and hold the Carbon Fiber Panel in place.
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Using a Dremel, I drilled out, and then expanded a hole in the snap support so that i could run a piece of aluminum through it. This will be used to support the piece of Conceal-x in the dash. Since the toggles are a little tough to throw (to prevent accidental throwing) I wanted to make sure that both the top and bottom were secure. I held these in place with 3/4 inch 10/32 stainless bolts and nuts.

Back wiring of switch panel
Wiring of Switch panel, and aluminum supports for panel.
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The wiring, drives off the cigarette lighter. NOTE: This will ONLY be used to power relays so the current draw on the cigarette lighter is minimal. I wouldn't suggest wiring the power for whatever you are switching in this manner.

I cut the existing cigarette lighter connector off it's wire, about an inch down the wire, and used some bullet connectors (alternateing male and female so the right polarity get connected every time) to make it easy to hook the whole shebang up, or to remove it.

The last step was to put it in the truck, and connect up the remote wires.