Rocket Man's 2008 Bagged CC Silverado Build AKA "THE MACHINE"

[kbuskill]

Exactly. I always have to make myself step back even when I have time. Otherwise I’ll just keep plowing ahead even if I need to redirect myself down another path. Which usually ends with me getting pissed off and failing or doing something I’m not happy with later and I always end up redoing it anyway.


So I was thinking and due to the tight area at the back of that dash hole I think I’ll drill holes all around the perimeter, making each one join with the one next to it and remove the rectangle that way, and then use my die grinder to clean up the edges. I have done that with aluminum a lot at work, cutting door hinges into storefront frames in the field. Those had to be perfect, and it was nice flat soft aluminum, but I’m sure I can do an acceptable job on this slightly rounded steel.

So I'm guessing that metal piece is relocated on the Esky?

This is the first I have heard of anyone having this issue with swapping the Esky cluster into a non-Esky.

I am certain you will figure it out, you have certainly overcome much more difficult situations with your rigs.

 

[Rocket Man]

So I'm guessing that metal piece is relocated on the Esky?

This is the first I have heard of anyone having this issue with swapping the Esky cluster into a non-Esky.

I am certain you will figure it out, you have certainly overcome much more difficult situations with your rigs.

I guess so. I don’t think anybody else uses the original connector. I looked at every parts list and every website I could find and couldn’t find one anywhere. If you use the plain style I had originally ( I bought the diagram, pins and connectors from @NathanJax so maybe that’s the only one you can buy) it fits because it lets the wires lay flat against the back of the cluster. Unless you go to a wrecking yard and cut the connector off a donor vehicle. The difference is probably 3/4” of extra clearance needed.

 

[iamdub]

So I was thinking and due to the tight area at the back of that dash hole I think I’ll drill holes all around the perimeter, making each one join with the one next to it and remove the rectangle that way, and then use my die grinder to clean up the edges. I have done that with aluminum a lot at work, cutting door hinges into storefront frames in the field. Those had to be perfect, and it was nice flat soft aluminum, but I’m sure I can do an acceptable job on this slightly rounded steel.

Would this simplify it?

 

[Rocket Man]

Would this simplify it?

View attachment 350920

Sure. You gonna buy me one? Wait… I just zoomed in…Central Pneumatic… HF…. Search… $38? Pretty cool tool. Hmmm.

Edit: I just realized I don’t have to pay to have the cluster programmed so I saved $90 there. Plus I’m sending the body controller back to Amazon so that’s $75 back. I got off pretty cheap on the fix for my mistake so I’m gonna get that tool tomorrow. I might never need it again but if I do, I’ll have it. I have the air recip saw that I bought 20 years ago and I’ve used it a few times so I’ll probably find a use for this one. Thanks for the heads up.

 

[Rocket Man]

It’s done, cluster is in and working. That air cutoff tool was about worthless, it’s so weak it barely cuts through plastic which is what I used it for. I ended up drilling a bunch of perimeter holes and using my air recip saw to get the majority out but at the top it curved backwards so I ended up using the whatever it takes method which involved clamping it with vice-grips and bending back and forth until it gave up and broke off. I used a did grinder a bit too. I broke the only saw blade I had right as I was finishing with it. I added some closed cell foam behind it because the top mounts aren’t in the right place for the cluster, just the bottom ones. There was always a small gap at the bezel and now the cluster gently pushes against the bezel I made, keeping the gap tight. It actually looks a bit cleaner than before.

 

[Rocket Man]

You know, now that I think of it, it’s probably not necessary to cut that hole for the plug IF you make your bezel to fit afterwards. The bezel I made ( remember you have to use parts from the Esky bezel and parts of the LTZ Silverado/ Tahoe bezel and epoxy them together. It involves trimming the back part of the Tahoe bezel where it meets the curve of the Esky cluster) was built for how the cluster used to fit with the other plug. So when I went to install my bezel that I had spent 20 or so hours to make, it was about 1” too wide at the top the way the cluster was sitting with the bigger plug. So in theory, you could make your bezel to fit the narrower gap. I just wasn’t going to mess with that one I made, it took forever to build it and make it look perfect plus I went through at least 4 Esky bezels and 4 Tahoe ones.

 

[iamdub]

It’s done, cluster is in and working. That air cutoff tool was about worthless, it’s so weak it barely cuts through plastic which is what I used it for. I ended up drilling a bunch of perimeter holes and using my air recip saw to get the majority out but at the top it curved backwards so I ended up using the whatever it takes method which involved clamping it with vice-grips and bending back and forth until it gave up and broke off. I used a did grinder a bit too. I broke the only saw blade I had right as I was finishing with it. I added some closed cell foam behind it because the top mounts aren’t in the right place for the cluster, just the bottom ones. There was always a small gap at the bezel and now the cluster gently pushes against the bezel I made, keeping the gap tight. It actually looks a bit cleaner than before.

Glad it's done!

That sucks about the cutoff tool. After using a few different Central Pneumatic cutoff tools (just not extended), I had higher expectations for it. Either that one was defective or it's why there's the ~$40 ones then there's the ~$200+ ones. No in-between. I've been binging on Hot Rod Garage and an extended cutoff tool seems to be a favorite. I'm sure it's one of the expensive ones, though. You have enough compressor?

 

[iamdub]

You know, now that I think of it, it’s probably not necessary to cut that hole for the plug IF you make your bezel to fit afterwards. The bezel I made ( remember you have to use parts from the Esky bezel and parts of the LTZ Silverado/ Tahoe bezel and epoxy them together. It involves trimming the back part of the Tahoe bezel where it meets the curve of the Esky cluster) was built for how the cluster used to fit with the other plug. So when I went to install my bezel that I had spent 20 or so hours to make, it was about 1” too wide at the top the way the cluster was sitting with the bigger plug. So in theory, you could make your bezel to fit the narrower gap. I just wasn’t going to mess with that one I made, it took forever to build it and make it look perfect plus I went through at least 4 Esky bezels and 4 Tahoe ones.

Dat deep look, doe.

 

[Rocket Man]

Glad it's done!

That sucks about the cutoff tool. After using a few different Central Pneumatic cutoff tools (just not extended), I had higher expectations for it. Either that one was defective or it's why there's the ~$40 ones then there's the ~$200+ ones. No in-between. I've been binging on Hot Rod Garage and an extended cutoff tool seems to be a favorite. I'm sure it's one of the expensive ones, though. You have enough compressor?

Yeah, plenty of compressor. The thing starts slowing as soon as you lightly touch anything. It cuts plastic but even that’s slow, I really had to baby it. I might take it back and swap it out for another to see if I just got a lemon. My air saw worked great, and I know it takes a ton of air. You get what you pay for,I’m sure. I’ll still keep it, if you need to cut plastic or super thin metal in a hard to reach area it will be great.

 

[iamdub]

Yeah, plenty of compressor. The thing starts slowing as soon as you lightly touch anything. It cuts plastic but even that’s slow, I really had to baby it. I might take it back and swap it out for another to see if I just got a lemon. My air saw worked great, and I know it takes a ton of air. You get what you pay for,I’m sure. I’ll still keep it, if you need to cut plastic or super thin metal in a hard to reach area it will be great.

Thanks for being the guinea pig. I'm always looking at them when I go there but, unless I have a need for it at that moment, I don't get one. I definitely won't get one if I have to spend the big bucks to have one worth bringing home. I've made it this far without...