Well, I soon will be taking the plunge and seeing how hard it is to do a manual 4th gen console swap. I will need to figure out how to wire up some switches for my power windows and power mirrors as well, and I know that involves cutting holes in the console. My question is, what is the preferred method to do this type of cutting? In my limited experience, I have found that Dremels and the like create a huge amount of heat which melts the platic you are trying to cut, making precision difficult. I'd appreciate any guidance you can give.

Also, I've done a search, and found some ideas for what kinds of window switches and mirror switches to use, but there seems to be a lot of info to digest. If someone has a fairly simple swap that they did, I'd be very interested in hearing what switches were used, how they were mounted, and how they were wired up.

Many, many thanks in advance. My fiance will be super-excited to finally have her cupholders in the car!

 

I bet one of those zip tools with a small bit would do a great job.

 

Ok, I spent even more time combing through different search results. Both the Contour and Saturn window switches appeal to me, as does the 4th gen mirror switch.

My question now involves what I need to get with the switches. Is a "pigtail" or whatever you call it that plugs into the switch, available new from GM for the 4th gen window switch? Do I need it, or can I use my thirden switch wiring? If I find Contour or Saturn window switches, do I need any of their original wiring as well?

Oh, and with the window switches, the ones I have seen on Ebay for the Saturns seem to come attached to a larger plastic bezel. Do you remove them from this bezel and then fab up a mounting plate to put them in the ashtray of the 4th gen console?

I know I have a lot of questions, but I have done a few searches to get me started.

Lawrence, I do have a Rotozip...

 

Do NOT use a high speed tool to cut plastic. As you stated, it will melt. Use a good quality drill bit in a cordless drill. Start slow and use slight pressure. Let the bit do the cutting, and you will get a nice, clean hole.

If you need to make larger holes/sqaures, use the drill bit for the corners. Then you can use a sharp utility knife and a hack saw blade to finish the hole. Put down some masking tape before you start, and draw the lines on it.

 

I can agree with you about using some tape around the holes or squares you are cutting, but a roto zip does a fast, clean job that will not melt any plastic. Maybe I should not have said this to you because you will delete my post
Good luck on the work and please show us some before, during, and after pictures.

 

Good idea about the masking tape, I wouldn't have thought to do that on my own.

Lawrence, I'll take some pics, but I won't share them if I end up doing a cruddy job!

 

Practice on a similar piece of plastic first, that way you can be sure.
Good luck on your conversion.

 

Why would I do that? If you have used a Roto to make clean holes in plastic, then it is good technical advice. I have always used the tried and true method of slow and steady when dealing with plastic. Granted, I have used power saws to make cuts in large panels of plexi, but for small holes, I would only use a drill/sharp knife.

 

use a hot knife to cut it

 

i used a dremel and cutting blade with NO melting issues and all of my lines came out as planned.

this is also a pic of what i did with my mirror button and used a dremel to cut that hole as well.
take it slow and dont hurry the blade thru and there wont be any melting.

http://www.pontiactorque.com/quickch...sole_00007.JPG

http://www.pontiactorque.com/quickch...sole_00014.JPG

http://www.pontiactorque.com/quickch...sole_00002.JPG