Third Generation F-Body Message Boards - 82-90 Firebird Intellitronix LED digital gauge install / review

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82-90 Firebird Intellitronix LED digital gauge install / review

This write-up and review covers the Intellitronix DP3001 LED digital gauge kit. Their website has this advertised as an "Easy install" and a direct fit system for 82-90 Firebirds. The description also states this kit features turn signals and high beam indicators which isn't the case (I think maybe just the thirdgen Camaro kit has that).
I purchased this new a couple years ago for a 1984 Trans Am I am building and am finally at the point where I can install it. While doing some research online before the install, I found quite a few people said they had dead LEDs on the boards and needed to send back to get fixed. I figured I should test the boards out to make sure everything is working properly before fully installing. I tested the boards using a battery charger and then fried a circuit. Luckily these have a lifetime warranty so after I contacted the company, I was able to send it back to get fixed. Customer service for that was great.
Now onto the install. The instructions seem pretty clear for how to wire everything up (which I haven't started yet), but they really have nothing stating how the circuit boards and black plexi covers get installed. You have to use your stock gauge housing and bezel. The first issue I encountered was the circuit boards did not fit into my stock gauge housing. The holes and notches in the circuit boards did not line up with some of the screw holes or the alignment pins in the upper corners. There is a large triangular opening in the speedo and tach circuit board that is supposed to fit around the blinker / high beam bulb housing but the board opening isn't large enough to fit around this. Using the upper right hand alignment pin, the other board with oil, temp, fuel and volts overlaps the raised screw mounting area in the lower right hand corner. Maybe these circuit boards fit great on other year thirdgen Firebirds, but it isn't working on my 1984. I sent these pictures to Intellitronix and asked how to install this or if I can exchange for a newer version that does fit.

https://cimg8.ibsrv.net/gimg/www.thi...d756fc5bb9.jpg

https://cimg2.ibsrv.net/gimg/www.thi...284458f380.jpg

https://cimg5.ibsrv.net/gimg/www.thi...78a9b472f9.jpg

https://cimg7.ibsrv.net/gimg/www.thi...882637e67e.jpg

Within 24hrs I received a tech call and was told I will have to modify my gauge housing. So much for their direct fit claims.
I didn't want to just go hacking up my housing so I took baby steps cutting things. I first cut off the top alignment pins. That didn't help the speedo / tach circuit board fit, but the other board was pretty close. I used a rasp bit on my Dremel at slow speed and enlarged the upper right hand screw hole slightly. Now the oil, temp, fuel and volt circuit board fits.

https://cimg8.ibsrv.net/gimg/www.thi...6b5fe96904.jpg

On the speedo / tach side, I tried shaving down the rounded pieces on the outside of the blinker / high beam housing. This allowed the circuit board to fit over the blinker / high beam housing, but the board was still way too high above the top right screw hole to mount it. The blinker / high beam housing is in the way but I didn't want to just cut it out. I ended up using a cutoff disc on my Dremel to make a slot in the blinker / high beam housing to slide the board down into place. The board now fits, but the screw hole above the steering column arc is way off from the mounting hole in the housing. Not sure if I want to try cutting a new hole. With my luck I'll ruin the board somehow and this thing won't work.

https://cimg1.ibsrv.net/gimg/www.thi...c1485b968c.jpg

https://cimg3.ibsrv.net/gimg/www.thi...c95fdd1f52.jpg

https://cimg4.ibsrv.net/gimg/www.thi...87dac28cd7.jpg

With the boards now fitting, I figured the rest should be easy. The next step is to install the front black gauge housing that was removed to install the circuit boards. Reinstall this using the screws that were removed when you took the cluster apart. The black plexi pieces sit on top of this black housing. It isn't clear whether these are held in place by the original clear lens of the cluster or by the large black gauge bezel on the dash. I tried using just the dash bezel, but then the plexi piece move around some back there - they just aren't held tight in place. I then tried installing the clear lens but the speedo / tach plexi cover doesn't fit at all inside the clear lens - mainly around the turn signal / high beam.

https://cimg8.ibsrv.net/gimg/www.thi...1cc8e75eec.jpg

I sent the picture above to Intellitronix and asked how the plexi is supposed to be installed. Their response was one sentence - "Sorry but you will need to modify that". Now I'm starting to get pretty PO-ed. This thing costs about $400 and the customer is responsible for modifying the hell out of their original housing AND the Intellitronix product to fit correctly?? The whole reason I bought this in the first place was because of the features is offers and it was supposed to be direct fit. I was originally going to do a full Autometer dash, but didn't want to fabricate a new housing to fit all the gauges. I guess I'm just going to trudge through this install since I'm already this far. Hopefully the end product is worth it.
I'll post more updates as I make progress so this community is informed of what it actually takes to use this product.