Dashboard Design: Merging Modern Technology with Classic Aesthetics
The Fisher 30 is a classic motor-sailer that originally came equipped with a Volvo Penta MD3B engine. The dashboard design, supplied by Fairways Marine and Northshore Yacht Yards, was specifically created for this engine setup. Over the years, however, exposure to sunlight, modifications, and aging took a toll on the original panel. It was time for an overhaul – one that preserved the traditional aesthetic while incorporating modern technology.
Assessing the Old Dashboard
Before embarking on the redesign, I conducted a thorough examination of the existing panel. The original dashboard proudly featured engraved “Volvo Penta” branding, reinforcing its authenticity. However, several issues had developed over time:
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Faded and damaged plastic: Prolonged UV exposure had rendered the panel brittle and discolored, making engravings hard to read.
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Compromised mounting points: Cracks and torn sections made secure installation increasingly difficult.
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Inconsistent modifications: Over the years, additional switches were installed in various styles, disrupting uniformity.
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Multilingual labeling: Some labels were in Dutch from the boat’s time in the Netherlands, leading to potential confusion.
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Deteriorating wiring: Corroded connectors, loose terminals, and an overall tangled mess behind the panel caused electrical failures and unreliability.
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Given the extent of these issues, a simple refurbishment wasn’t enough. A complete replacement was the best course of action to ensure long-term durability while maintaining the classic aesthetic.
Planning the New Dashboard Design
Initially, I considered refurbishing the existing panel by replacing worn-out switches and rewiring the internals. However, due to uneven hole sizes and material degradation, I opted for a completely new dashboard. The challenge lay in crafting a panel that felt true to the original while enhancing functionality.
Key Features to Preserve:
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Three primary engine instruments: The tachometer, temperature gauge, and hour meter, all positioned as per the original layout.
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Warning indicators: Oil pressure warning light and charge indicator are crucial for monitoring engine health.
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Ignition switch and Horn location: Retaining its familiar placement for consistency and ease of use for the horn button while optimizing the location of the ignition switch.
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Dimmer control: Allowing adjustable lighting levels to reduce glare during nighttime navigation.
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12V cigarette lighter socket: Providing additional power options for onboard electronics.
Modern Enhancements:
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USB charging ports: To power mobile devices and accessories onboard.
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LED backlighting with dual color mode: Ensuring clear visibility of switches and labels at night. (Red & White)
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Upgraded materials: Using UV-resistant, water-resistant acrylic for long-term durability. Improved aesthetics by lasercutting instead of milling the labels.
Capturing Accurate Measurements and CAD Modeling
Since the goal was to develop a completely new dashboard panel, the first step was to take precise measurements. This included not only the overall dimensions of the panel but also critical details such as the exact positions and diameters of the mounting holes. To ensure accuracy, all these values were carefully noted before proceeding to the next stage.
Given the complexity of the layout and the need for high precision, I decided to create a digital model of the dashboard using Computer-Aided Design (CAD). This was done using Autodesk Inventor, which, although not necessarily the optimal choice for this type of project, was readily available at the time.
One of the challenges in this phase was accurately determining the center points of large cutouts. Measuring these directly on the original panel was prone to error. To mitigate this, I created a high-resolution scan of the existing dashboard rather than relying on a photograph, which would introduce optical distortion. A standard photo would cause parallel lines to appear skewed, making precise alignment difficult. By scanning the panel and importing the image into Inventor, I could scale it accurately to match the previously measured dimensions. This approach allowed me to precisely position all original elements in their correct locations.
A key aspect of the redesign was to ensure the new panel retained the authentic look of the original. This meant that all engraved text and labels had to be reproduced with exact precision. Notably, the “Volvo Penta” branding was placed in the exact same position, using the same font, thickness, and spacing as on the original dashboard. The same applied to other engravings, such as the “Built for Fairways Marine by Northshore Yacht Yards” inscription and all switch labels.
Next, I positioned the three primary engine instruments – the tachometer, temperature gauge, and hour meter – mirroring their exact locations on the original panel. Other crucial components, such as the ignition switch, oil pressure warning light, and charge indicator, were also retained in their original placements for consistency and ease of use.
One element that was removed during this process was a previously added battery voltage meter. Since this component was no longer functional, it was omitted from the new design. Future battery monitoring will be handled through a power management system, making a dedicated dashboard gauge redundant.
The redesign left ample space on the panel for creative and functional upgrades. One of the first improvements was the integration of a USB charging hub. While not always necessary on a dashboard, it provides a convenient charging solution for onboard devices. The hub was designed to accommodate both USB-A and USB-C ports, with a power output of up to 115W – enough to charge even a laptop.
In keeping with the boat’s classic feel, I also opted to reinstall a 12V cigarette lighter socket. This not only preserves the nostalgic aspect of the vessel but also serves as a versatile power source for various accessories, such as air pumps or portable chargers.
Switch Arrangement and Nighttime Readability Enhancements
On the left side of the dashboard, I focused on the arrangement of switches that control various onboard systems. A structured layout was designed, ensuring both functional grouping and a visually balanced appearance. Extensive research was conducted to determine which electrical components should be operated directly from the dashboard, aiming for a complete and future-proof design that would not require modifications later.
A key feature carried over from the original dashboard was the ability to dim the instrument lighting for night navigation. This functionality had proven to be invaluable, so I included a dedicated dimmer knob in the new design, allowing the main instruments to be adjusted for comfortable nighttime use.
At this stage, a new idea emerged: rather than engraving labels into the panel surface as before, the text could be backlit. This would allow for adjustable illumination levels and the ability to switch between white and red lighting. Red backlighting is particularly useful at night as it reduces glare and preserves night vision. With this dual-color functionality in mind, the switch layout was finalized and incorporated into the dashboard design.
Material Selection
With the design finalized, the next step was to select a suitable material for manufacturing the panel. While I was able to locate the original material used in the old dashboard, I ultimately decided to go with a modern alternative that would address some of its shortcomings.
The original panel featured engraved lettering, which, over time, accumulated dirt and became harder to read. Additionally, traditional engraving does not allow for backlighting. To overcome these issues, I selected Transacryl, a dual-layer acrylic material. This consists of a transparent acrylic base coated with a black surface layer. When laser-etched, the black coating is precisely removed, allowing for backlighting of the text and symbols. This material offered several advantages:
UV resistance: Ensures long-lasting clarity and durability.
Smooth, easy-to-clean surface: Prevents dirt buildup in the engravings.
Enhanced visibility: Allows for LED backlighting without excessive glare.
Superior aesthetics: Provides precise laser engraving for a professional finish with sharp details.
Chemical and moisture resistance: Makes it ideal for a marine environment.
With the material chosen and the design finalized, I prepared a detailed 2D technical drawing to serve as a blueprint for manufacturing. This drawing included precise dimensions for every cutout and engraving, ensuring a seamless production process.
A suitable manufacturer was selected to laser-cut the panel according to the design specifications. This approach not only ensured high precision but also allowed for the seamless integration of backlit text and symbols.
With the dashboard panel fabricated, the next phase of the project involves ordering the necessary components and assembling the final unit. This includes installing the switches, gauges, lighting elements, and wiring everything together to create a fully functional and visually refined dashboard.