Crafting a Custom Aluminum Dashboard for Your Moto Guzzi ‘Jackal’

Why a Custom Dashboard?

A tachometer is an essential tool for any motorcycle enthusiast, providing real-time data on engine speed. Unfortunately, finding a new or second-hand Cali EV dash for your Moto Guzzi can be challenging. This is where a custom dashboard comes into play. Not only can you create a dashboard that meets your specific needs, but you can also design one that surpasses the original in both form and function.

Materials and Tools You'll Need

Before diving into the project, gather the following materials and tools:

• 4mm thick 1050-H14 aluminum (BS 1470): This is 99.5% pure aluminum.
• Wet & dry sandpaper
• Drills and a countersink
• Hole cutter for 85mm diameter holes
• Basic hand tools
• Small band saw
• Files and medium/fine flap wheels

Advanced Cutting Methods

For those with access to more advanced tools, consider using:

• Water Jet Cutting
• Plasma Cutting
• Laser Cutting
• CNC Milling

These methods can provide smoother and more precise results.

Step-by-Step Guide to Cutting Your Dashboard

Marking and Drilling

1. Mark out the plate: Include the profile and hole centers.
2. Center-pop all hole centers: Use a sharp center-pop and a light tap.
3. Pilot drill each hole center: A 1/16th drill works well.
4. Cut the 85mm holes: Use a trepanner, tank cutter, or an 85mm hole saw.
5. Drill the warning light and mounting holes: De-burr the holes.
6. Finish the warning light holes: Use wet & dry sandpaper for a clean edge.

Shaping the Underside

1. Cut out the profile: Use a hacksaw, bandsaw, or plasma cutter.
2. Smooth and finish the edges: Use a file, wet & dry sandpaper, wire wool, and a flap wheel.
3. Bend the mounting lugs: Use the original dash as a pattern.
4. Surface finish: Hold the drill with both hands and run the flap wheel down the dash in one smooth, even stroke.

Final Touches

1. De-grease the dash: Use Methylated spirit, avoiding finger marks.
2. Spray with acrylic lacquer: Apply a few coats for a polished finish.

Installation and Wiring

For fitting and connections, the speedo cable should fit fine. For wiring assistance, refer to the article “Install a rev counter on your motorcycle”. While the process may seem complex, the end result will be a custom dashboard that enhances both the look and functionality of your Moto Guzzi.

Interesting Stats

• Motorcycle Customization Market: The global motorcycle customization market is expected to reach $12.4 billion by 2027, growing at a CAGR of 5.1% from 2020 to 2027 (Source).
• Aluminum Usage in Motorcycles: Aluminum is increasingly used in motorcycle manufacturing due to its lightweight and corrosion-resistant properties. Approximately 20% of a modern motorcycle's weight is aluminum (Source).

Creating a custom aluminum dashboard for your Moto Guzzi ‘Jackal’ not only enhances your riding experience but also adds a personal touch to your beloved bike. With the right materials, tools, and a bit of patience, you can craft a dashboard that is both functional and aesthetically pleasing.