Ok, I finished installing a gauge on an '02 Explorer and it required total customization. I selected the rectangular gauge because there seemed to be a perfect location for a gauge in the center console just below the climate controls.
Boy was I wrong! When I removed the center console there was hardly any room. There seemed to be somewhere between 1 to 2 inches of space, but it was hard to tell with the center console portion removed. I knew the original gauge wasn't going to fit, but I was going to make it fit if I could.

So first I needed to figure out how much space there was to work with. I decided to mold some clay like substance in there and figure out the shape and depth. I used some of that Crayola modeling clay that drys pretty good in a day.

So the mold comes back and I have around 1 1/4 inches of space max. I knew it was tight but the gauge takes 2 inches of space assuming you cut some bolts to make it that small.

Ok the gauge comes apart and I notice what's making it so large. There are spacers keeping the display off the lense (can be shortened), the two boards are separated by more than they need to be (require some desoldering and resoldering here) and one of the boards has components that are too tall. Seven components in all would need to be changed if there was any hope of making it fit. The way it is mounted is convenient, but wastes space also - needed a new way to mount it. Resorted to basically gluing it in.

Ok the aluminum cover, couldn't work it out to make it small enough went with bare boards (silicon to insulate parts that might short).

Bottom line: I ended up with a component that was close to the 1 1/4" limit and most importantly it fit!

Oh yeah, I would be remiss if I didn't mention that I got help from my Wife! I needed her buy-in to cutting up the truck, so I just involved her and she helped with some soldering and cutting suggestions! She really didn't trust me to cut the hole but it ended up perfect in the end. We live in peace :)

Pic's to follow

You are truly a great pioneer!:)

pictures!!

!

Here's a picture of the gauge fully installed (first attempt at adding pictures so hope it works!)

http://members.telocity.com/rgiles/Explorer/ExplorerGauge02014.jpg

Here's the area I had to work with:

http://members.telocity.com/rgiles/Explorer/ExplorerGauge02012.jpg

Here's the molded clay with the original gauge next to it so you can see how it isn't going to fit!
http://members.telocity.com/rgiles/Explorer/ExplorerGauge02015.jpg

This is the backside of the panel with the fully modified gauge installed and ready to go.

http://members.telocity.com/rgiles/Explorer/ExplorerGauge02011.jpg

Looks good. The gauge matches the other displays really well.

You didn't need all the extra weight from the gauge housing anyway.:)

That came out really good. Way to go!

very nice!

lol extra weight. Yep coulda hurt my gas mileage ;)

In addition to the case, I replaced 3 capacitors (yellow in picture), removed two LED's, removed the cable connector, and replaced a potentiometer with a flat one (light blue top of picture). I also shortened the distance between the boards and the lens to the least possible and it still BARELY fit.

could you not just cut a hold to fit into that large peice of plastic behind there. Or is there something important inside that thing?

Originally posted by XLT_66
could you not just cut a hold to fit into that large peice of plastic behind there. Or is there something important inside that thing?

That thing looks suspiciously like an a/c /heating duct. I don't think you would want to hack into it.

That plastic is the air duct to the rear of the vehicle so I didn't want to touch it! You could think of doing something with it if you really had to, and believe me I was looking at any possiblities.

Originally posted by rgiles
In addition to the case, I replaced 3 capacitors (yellow in picture), removed two LED's, removed the cable connector, and replaced a potentiometer with a flat one (light blue top of picture). I also shortened the distance between the boards and the lens to the least possible and it still BARELY fit.
Well, if you figured out how to do all that, you should have no trouble figuring out how to change the blinker fluid. I still cant find the drain plug. :banghead:

Originally posted by 98FordX24
Well, if you figured out how to do all that, you should have no trouble figuring out how to change the blinker fluid. I still cant find the drain plug. :banghead: LOL, i can do all that but some of the other simple things baffle me too. If I ever find the drain I'll let you know :confused:

wow, i just posted like 2 mintues ago, and there is already like 3 posts after me, the pages keep growing.

Yea, i guess cutting into the air duct would not be a good thing...

So now that I have your attention, what do you think about the idea of adding a switch to use the same gauge to monitor water temp? Couldn't monitor at the same time, but manual switching would be possible? I've thought about making it electronically switched as well.

Since I have no more room, I'm more motivated to use the same gauge!

Could add some gauges in the a-piller... looks good though!

Originally posted by RFR2212
Could add some gauges in the a-piller... looks good though! Thanks...I'm sure there must be pods for the A-pillar but I couldn't find any. The ones for the 96-01's don't fit so they need a new design.

Is the calibration of voltage to temp the same for a water temp and an oil temp sender?

I don't see why you couldn't switch back and forth from two oil type sensors (i.e. two trans temp senders at different locations) but I don't know if the reading will be correct for the water temp sender.

I would have to go with the 400 degrees F sending unit. So long as they are the water and tranny have the same rating it should read correctly I would think. The water sending unit is normally 300 F unit.

It sounds like it should work then as long as the temp senders have the same range.

I am thinking about running two trans temp senders - one located on the cooler line at the trans for the high temp; the second one located after the trans cooler so I can see what the cooler performance is. Is that anal or what?;)

This might actually happen over Xmas holidays while the GF is out of town.;)

I have my temp sender and filter mounted right before it goes into the cooler. Now that its getting colder outside it hardly gets above 100*. In the summer it's gone up to 175*.

Originally posted by 98FordX24
I have my temp sender and filter mounted right before it goes into the cooler. Now that its getting colder outside it hardly gets above 100*. In the summer it's gone up to 175*.

I've seen mine go up to 187 and it was only 65 degrees out. It hovers around 155 at 70 mph on the freeway. It never hangs around 100 it usually climes up to around 130-160. Mine is also before the cooler. I wonder why such a difference?

When I went 70 MPH on the highway in about 60* weather it stayed 123* constant. Oil pressure stayed at 41 psi. Not sure why there is such a difference.

FWIW
I have 2 sending units for trans temp in the stang. One is at the aux. filter before the coolers. This is reading fluid temp from the converter.(hottest)
Second sender is in the pan. Toggle back & forth with a SPDT switch.
On real hot days (85 to 95) with engine temp at 210 to 220, there will be as much as 15 degrees diff in temp. Will run as high as 190 + from the converter.
In colder weather (40 to 50) trans temp doesn't go much above 125.
Gauge is an autometer elec.