David Ander son posted this sometime back:
To print these out to the correct size, right click on an image and Save Image As the four pics posted below to your hard drive and open each with a graphics program that will allow you to print the image at 100%. They were scanned at 100 dpi. XP Printing Wizard will not work to print the image to exact size. You will need Photoshop, Photofiltre, Irfanview, or something like that. To check if you are right the width of the fuse box opening is 4⅛".

You can use Microsoft Paint if your printer will accept these settings.

In the first post right click on the image with the 4-1/8" measurement on it and "save picture as" to your desktop as a .jpg. Go to you desktop and right click on the .jpg and open with Paint. In Paint go to File and then Page Setup. Set Size to Letter (8.5 X 11 .in), Set your margins to .25 on the sides and .5 on the top and bottom. Use Portrait Orientation and Adjust to 100% normal size and click OK. Print and measure the opening for the fuse box, if it measures 4⅛" then you have got it right and can do the other three.

After you have figured out how to print them to the correct size you can tape them together by lining up the dotted lines and where they intersect in the center. Cut it out with scissors and a razor and transfer to a stiffer kind of paper.

Then transfer to a sheet of LEXAN (Available at HomeCheapo), cut out on a scroll saw, paint the underside, and Bob's your uncle.

Have fun, and Good Luck.

***************************************

Mahalo David. I made the template and as I have no tools or SKILL for cutting plastic I took it to my local plastics shop. They wanted about $50 for the material and labor. That's the cost of the cover out of a catalog (+ shipping. $15) No Deal!

However, I was told if I could get the complete cover in one piece , as opposed to four, in a either a Corel Draw v9,.cdr, .pdf, .eps or .al file they could transfer the file of the drawing into their laser cutter and and do it for a lot less.

David, can you or someone do that and send it to me? My alternatives are to either pay for one out of the catalog and pay the high shipping fee to Hawaii or do what you suggest and buy a piece of Lexon and a scroll saw and "practice" till I get it right. More than likely a waste of my time and money.

DJ
Hawaii

 

I think I'm missing something here; where's the template?

 

 

Original post -

http://forums.corvetteforum.com/show....php?t=1655160

I think I now know what I'll be attempting this weekend!

 

here is the link to the post with the template....
http://forums.corvetteforum.com/show....php?t=1655160

It really isn't that hard to do. I didn't have any experience with cutting plastic or anything else and mine came out pretty good. Just get a big enough piece of lexan so if you mess up then you can do it again. Part of the fun was actually trying to make it as good as I could. I even made a JAke logo....

 

Thanks, I may just have to bite the bullett and do it myself unless someone can figure out how to get the template pieced together in a file the lasser machike can read....

How thick was the lexan you used? I'm thinking 1/8".....

 

yep. 1/8 is what I used. I would go and buy a Dremel if you don't already have one. That made it waaaaaay easier.

 

A`ole pilikia DJ,

My original thread is intended for the normal joe with a home printer that's limited to letter sized paper. That's why the template is divided into 4 parts.

You can download a full size .pdf file here.

The original thread can be found here.

David

 

Mahalo nui loa, David. I'll give that a try as soon as I get back from town. I'm running late right now.

Aloha kakou,
Kenika

 

So I'm looking at this post again thinking how I'm going to get my hands on the template (run Vista, haven't bought a compatible printer yet) then it dawned upon me - LEXAN IS CLEAR!!

So I went and got a couple of 2'x2' sheets, took one and cut it down a bit, layed it over the compartment and traced it out with a Sharpie. I've got it rough at this point without the cutouts for the box, latch, or stop; took 15 minutes.

Anyway, once I get all cuts done and paint I'll post a pic.

 

And easy cheap mod.... I know the wife would let me do that kind.....

 

I just printed out the template using "Paint". I followed the instructions as described and it it turned out perfect. I've been eyeing this project for a while and now think I may pursue it further since the template was the part I was fretting over. I guess now I need to look at buying a dremel and a sharp blade for my scroll saw. Hope to get around to doing this real soon. Thanks for the template and instructions.

 

 

As promised, here are a few pics. Total time invested, a couple of hours.







First I want to make it known that I realize the paint doesn't match the exterior! I'm actually thinking of using the mirror product DeeGee spoke of in a post of his a couple of days ago. Bottom line - super easy to do mod.

 

Looks great

Where did you get the materials and what was the approximate cost?
Thanks

 

You can buy 1/8 plexiglass or lexan for $6.00 to $14.00 from homedepot or lowes.

I used a spray can of kyrlon fusion for plastics to paint it. Believe it or not a local Kmart had more colors than most department or auto stores

 

Remember, you need a Dremel to cut the Lexan, and go at low speed.

 

I got my first piece of LUCITE at Menards here in Indy (not sure if they are a national chain, but think Home Depot, Lowes) After it cracked on me while test fitting, I got a piece of what I think is LEXAN from my dads work. He is a vending repair guy and it is the stuff that they use for the trademark panels on pop machines. I can say that without a doubt that this stuff is strong. I finally got mine done, now I just need to finish up the Jake logo to glue on.