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  • 9 Post By petrolhead_chn
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Thread: ---Custom Speedo Gauge Dial---

  1. #1
    Rusted petrolhead_chn's Avatar
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    Default ---Custom Speedo Gauge Dial---

    ---Custom Gauge Dial---

    Vehicle:

    Bajaj Avenger (common for most motorcycles)

    Purpose:
    The existing dial has been given a vintage look by Bajaj. I wanted to change the looks of it. To me it seemed dull and not so interesting when I lay my eyes on it.

    Materials required:

    1. Adobe Photoshop software
    2. Scale
    3. Pencil
    4. Permanent marker - Black
    5. Sketch pen - Black
    6. Scissors
    7. Old refill of reynolds pen
    8. Crafts knife
    9. Fevibond
    10. A red color or colored bulb as per wish
    11. Clear spray (optional)

    Tools required:

    1. Speedometer removal - 10" ring spanner
    2. Phillips/star screw driver - dismantling the cowl, gauge and needle from the unit
    3. Pliers
    4. First aid kit ;-)

    Procedure:

    1. Remove the speedometer unit from the handlebar using the 10" ring spanner. Remove the knob that resets the trip meter. There is a small screw inside the knob. Dismantle the unit.

    2. Pry out the speedo needle with some gentle force. You may clasp the needle and pull it out.

    3. Remove the 2 screws that retains the gauge dial to the meter. Remove any other object that may be stuck or screwed to the cowl.

    4. The reverse of the gauge dial should be compltely green. Do not attempt to sand the green away with nail polish remover or paint thinner. Please retain the old dial as you may need it in the future.

    5. Now, using the measuring the scale, measure the diameter of your gauge dial (on Avenger it is 8cms) and come up with a design and color combo that you wish.( I wanted to change the dial color to red color and add the Avenger logo in it)

    6. Open up a new photoshop document and create a canvas size of 8cms x 8cms and create the speedometer dial. Add designs that you want. Ensure that you keep in mind the cuts that you might have to do to display the meter readings.

    7. Once the dial is designed, you need to take a print out at a photo studio.

    8. Once the print is received, cut out the round dial from the print using scissors. Take help of the old dial and trace out the markings for needle, needle stop (at zero) and meter/trip meter numbers are displayed.

    9. Use craft knife to cut out the projections/boxes as necessary.

    (Important step)

    10. Once done, flip the dial and use the sketch pen to isolate the numbers and pointers. Use the black permanent marker and start coloring the blank spaces in which you do not want the light to penetrate. Do it evenly and slowly. Use the red marker to color the number and pointers.

    11. Let it dry for sometime and repeat the step 10 again.

    12. Once done, you can spray this side with clear coat (optional)

    13. Make holes for speedo needle and mounting screws on the new gauge dial.

    14. Assemble things back after ensuring that you use fevibond to paste any plastics that might allow moisture inside the assembly. Cut out about half an inch from old reynolds refill and paste it adjacent to zero as a way of stopping the needle dropping beyond zero.

    15. Replace the stock speedo bulb with a red bulb or any color of your choice. Please color the numbers and pointers in accordance to your color bulbs.

    16. In Avenger there is a plastic wall kinda mould where you insert the bulb. Ensure to break that away and this ensures even distribution of light inside the console.

    Results:

    Reassemble the parts in order carefully. Job well done if all is done well!
    I did not have time and the patience when I was nearing the final stage with my daughter running around and wifey calling for help and all that. I had to rush through. Ensure you have ample time towards the end. Preview your photoshop document before printing. REMEMBER THAT IT IS MY 2ND ATTEMPT THAT I GOT A MORE CLEAR AND SATISFACTORY RESULT. If only I was patient in the 1st attempt :-(

    ---DISCLAIMER---

    I am a fond lover of doable DIY projects. I have take utmost care and caution in doing this with all risks vested upon me. While the outcome may vary on each bike, I strongly recommend you to completely understand your bike and then go ahead with similar DIYs. Though I would be glad to answer any of your questions I am not responsible for any kind of outcome of such DIY.

    Please take help and clarify before gettings in to the job!!!
    Feel free to PM for any questions!

    Hope you all liked it.
    Thank you for reading!!!

    Now the pictures....

    Initial attempt

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    Initial result

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    Speedo designs - 2nd attempt

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    Final gauge dial
    Name:  3.1.JPG
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    Marking on the flip side of dial
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    Marking the numbers on flip side
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    Coloring the flip side of dial with black permanent marker
    Name:  6.JPG
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    Reassembled the dial, meter and needle in order
    Name:  7.JPG
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    Final output - a comparison
    Name:  Bajaj-Avenger.jpg
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Size:  39.9 KB Name:  8.JPG
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    Comparison b/w stock, 1st attempt and final results
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    A closer shot
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    Last edited by petrolhead_chn; 08-15-2013 at 08:32 AM.
    My DIY(s) - Sprocket bearing change | Paint job | Custom speedo dial

    Getting angry at somebody is the same as getting angry with a bike that just won't go. You should stop and start thinking.
    A good mechanic will let you watch even without charging you for it. | Riding faster than everyone else only guarantees youll ride alone.

    It is funny to know that we've been imitated and copied so well
    and surprising when we notice our mistakes are copied as well.

  2. #2
    Moderator The Monk's Avatar
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    Default Re: ---Custom Speedo Gauge Dial---

    DIY Approved

    Now please post the pics properly in between the text.
    SID_BHP likes this.
    Biking is not about what you have between your legs, its all about how well you use it!!!!!!!

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    Default Re: ---Custom Speedo Gauge Dial---

    very nice D.I.Y sir
    but how does you made a new surface plate ?
    or is there a paper printed surface plate ?
    petrolhead_chn likes this.

  4. #4
    Rusted petrolhead_chn's Avatar
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    Default Re: ---Custom Speedo Gauge Dial---

    Quote Originally Posted by harsh dts-fi View Post
    very nice D.I.Y sir
    but how does you made a new surface plate ?
    or is there a paper printed surface plate ?
    Thank you for liking it. And yes it is a thick photo paper print out.
    harsh dts-fi likes this.
    My DIY(s) - Sprocket bearing change | Paint job | Custom speedo dial

    Getting angry at somebody is the same as getting angry with a bike that just won't go. You should stop and start thinking.
    A good mechanic will let you watch even without charging you for it. | Riding faster than everyone else only guarantees youll ride alone.

    It is funny to know that we've been imitated and copied so well
    and surprising when we notice our mistakes are copied as well.

  5. #5
    Rusted princesirohi's Avatar
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    Default Re: ---Custom Speedo Gauge Dial---

    the printout was on paper or some other material..??

  6. #6
    Rusted petrolhead_chn's Avatar
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    Default Re: ---Custom Speedo Gauge Dial---

    Quote Originally Posted by princesirohi View Post
    the printout was on paper or some other material..??
    The regular paper that the photo studio guys use for karizma albums.
    My DIY(s) - Sprocket bearing change | Paint job | Custom speedo dial

    Getting angry at somebody is the same as getting angry with a bike that just won't go. You should stop and start thinking.
    A good mechanic will let you watch even without charging you for it. | Riding faster than everyone else only guarantees youll ride alone.

    It is funny to know that we've been imitated and copied so well
    and surprising when we notice our mistakes are copied as well.

  7. #7
    Rookie DebayanS's Avatar
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    Default Re: ---Custom Speedo Gauge Dial---

    nice DIY.. though of doing something same on my avy..
    but am stuck at a point... how did you remove the reset button from the bin??

    Can you please guide me , it would be very elpful...

    Cheers
    Ride hard, ride Safe!!
    Bikes don't leak oil,
    They mark their Territory.

    Bajaj Boxer -> 2003 - till date
    Bajaj Avenger -> 2011 - till date
    More to be added :-)

  8. #8
    ~AJ
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    Default Re: ---Custom Speedo Gauge Dial---

    [QUOTE=petrolhead_chn;979254]---Custom Gauge Dial---

    1. Remove the speedometer unit from the handlebar using the 10" ring spanner. Remove the knob that resets the trip meter. There is a small screw inside the knob. Dismantle the unit.

    hi
    could you please elaborate on how did you dismantle the unit?
    I am having difficulty removing the metal ring holding the glass to the speedometer plastic casing..

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