Cutting Electrical Panel

[Head Sail]

I need to add three new switches for an autopilot. I have an abandoned area on the old switch panel that I was thinking of cutting out but don't know how to accurately cut a square hole to insert the new switches with their bezels. The panel is plastic about 1/16 thick. Jigsaw sounds a little hazardous. Has anyone have any experience with this?

 

[agprice22]

Dremel with a cutting wheel?

 

[uncledom]

I use a dremel with a drill type cutting bit and square it of with a small file. Keep a good grip on the dremel or drill if you use one of those as bits walk easy in plastic.

 

[joker460]

I've used this http://www.elitetools.ca/en/product/multi-max-mm40-04-tool-kit-dremmel-mm40-04/. Works great!

 

[agprice22]

One way I keep a drill bit from walking, especially on tube, which I know this is not, is to cut a shallow, small X at the drill spot with the thinnest dremel cutting wheel. The cuts open up the surface, and the bit sits right in the crux of the X. The drill hole removes all or most of the X.

 

[sesmith]

Vibrating multi tool works great for this sort of thing. Dremel and Fein make them as well as others.

edit...just noticed joker 460 already linked to the dremel one. I have that one, and it's one of the most used tools I have for boat work.

 

[woodster]

If the panel is phenolic it will chip real easley the best way is with an abrasive circular blade and for holes is best to use a plunge router of with the proper size bit

 

[Head Sail]

I believe it is phenolic. Maybe less risky to slowly drill holes and use toggles instead of rockers.

 

[woodster]

I believe it is phenolic. Maybe less risky to slowly drill holes and use toggles instead of rockers.

it will chip for sure ...it takes a carbide high speed bit to cut that stuff....

 

[Bill Roosa]

what the heck do you need three switches for? The AP is either on or off. You should be able to wire it so a single switch turns it on and off. Perhaps I'm missing something.

 

[Head Sail]

what the heck do you need three switches for? The AP is either on or off. You should be able to wire it so a single switch turns it on and off. Perhaps I'm missing something.

The manufacturer calls for individual circuits for the SeaTalk network, ACU, and MFD. It does sound like overkill but I figure they know what they're talking about.

 

[Mark Maulden]

All this power!! Drill a hole and put a coping saw blade through it and reattach saw and go sawing slowly. And you can double stake SeaTalk with ACU. This what i did and worked great until I added AIS. Now if i want MFD and AIS, i have to remember to turn the ACU on to power the bus. Im going to change and power the bus from MFD. just remember to fuse correctly and individually. My panel is getting full.....

 

[DougM]

Instead of cutting up your original panel, why not add a smaller sub-panel nearby and power that straight from the DC bus? Install your additional switches in it...

 

[Head Sail]

Instead of cutting up your original panel, why not add a smaller sub-panel nearby and power that straight from the DC bus? Install your additional switches in it...

This is a good solution since adding new capabilities and instruments in the future will require separate switches. But, I do have some "real estate" on the existing panel that can be put to good use...unless it cracks.
The power solutions are good to know. Thanks!
I like the simple solution of using a coping saw blade since it should be a very controllable cut and induce much less vibration than a power tool.

 

[Bill Roosa]

By seperate circuits do they mean protection??? ie each of the devices need a different fuse size (amps to blow).
If so then you can put everything on one switch and put inline fuses after it. Just make sure the main switch (circuit breaker) has sufficient amp rating to handle all the loads.

 

[Head Sail]

By seperate circuits do they mean protection??? ie each of the devices need a different fuse size (amps to blow).
If so then you can put everything on one switch and put inline fuses after it. Just make sure the main switch (circuit breaker) has sufficient amp rating to handle all the loads.

No, they said separate switches and separate fuses. It could be tied into a single breaker as long as the breaker was sufficient to carry all max loads at once. May not be necessary to make the system operational but I can see how it would be useful to troubleshoot or add new instruments.

 

[wufibugs]

What size square do you have to cut out? Since this calls for 3 switches, you are probably talking a 1" X 3 1/2" rectangle? Take a slightly larger piece of plastic or 1/8 teak, mount your switches in it, and then mount that to the panel. That way you can cut the panel with this: http://www.harborfreight.com/oscillating-multi-tool-62279.html

 

[Ron20324]

How about a hot-knife or solder iron with the flat blade. Have to clean it up some afterwards, though.