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6 Switch Conversions

. Like most who have added off-road lighting to their TJ. I needed to find a place to mount the additional switches. Not wanting to take away from the clean appearance of my dash by just drill holes and mounting an aftermarket switch. I decided to try what is sometimes called the 6-switch conversion. The 6-switch conversion is done by replacing the ashtray with a 2nd 3-switch bezel. For those of you who would like to have the same look hear is a write-up of how I did it along with a few tips on how to do it yourselfer

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click images for larger view

Step 1

. Is to obtain the tools and parts necessary to do the conversion. The only new items you will need are a 3-switch bezel and of course some switches. A bezel from any 1997 to 2002 TJ will work. These can be found at most any salvage yard, on-line, and at your local dealership. Prices will very widely. So shop around.

The tools.

  • Philips Screwdriver
  • 6 in. plastic ruler
  • 18 in. steel ruler
  • Compass
  • Pencil
  • A peace of construction paper
  • Scissors
  • Spring clamps
  • Small Wood blocks wrapped in 150, 300 and 600 grit sand paper
  • A Dremel tool w/
    • 1 in. diameter fine & course cutoff wheels
    • ¼ & ½ in. sanding drums (med & fine)
    • ¾ & 1 in. sanding disks

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. Step 2

.Remove the top vent cover from the jeep. Just grab it and light up. It’s only held in by 5 spring clips and will pop right up. Now unscrew the two screws holding the top of the center trim bezel down and the one that is behind the ashtray. Pull the center trim bezel straight out (not up) it too is being held in place by 4 spring clips. Next unscrew the 4 screws holding the existing 3-switch bezel and remove it unplugging any wires that may be attached.

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. Step 3

.First I found a suitable location to work. Then I started by using a small cut-off wheel on a dermal tool I cut the bulk of the ashtray mount off of the center bezel

. As you can see in the pictures the plastic started to melt from the heat created by the cut-off wheel grinding away at the plastic. After the bulk of the ashtray was removed, I started to clean up the rough edges using ¼ & ½ in. sanding drums and ¾ in. sanding disk with a dremel tool.

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. Step 4

.Using a compass as a makeshift gauge I marked the edges to be trimmed off See pic #9 & pic #10. Then being care full not to melt the edges again I trimmed the edges down first with the dremel then with a small block of wood wrapped in sand paper. As I sanded it closer and closer to the line I kept test fitting the switch bezel for proper fit. Note :I left the far right hand edge a bit long so that I could trim it off later when I knew just how much of it had to go.

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. Step 5

.I removed the switches and cigarette lighter from one of the 3-switch bezel to make the bezel easier to work with. See pic #11. Then I cut the left mounting edge off and sanded down the 3 fins that were left sticking out. (image #12). Next using some paper I made a template of the right hand edge of the bezel. Using the paper template I marked the shape of the right side onto the left side of the bezel. See image #12, #13, #14, #15,

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. Step 6

.Now cut out what you have marked. But first go back and re check your marks and make sure you have marked it accurately. Be care full not to cut too much away. (Remember you can always cut or sand a little more off but you cannot put it back on so take your time.) The two bezels should now fit together like a puzzle. It is very important that the cuts are accurate and that they fit snug because the snug fit is what holds the 2nd switch bezel in place.

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. Step 7

.Now holding the two switch bezels together you will notice that the area where they fit together is not even. It’s a little wider at the top than the bottom. (See pic # 21) To fix I used a piece of 600 grit sand paper on a flat board to sand the left edge of the cut (2nd) switch bezel down till they fit together evenly (Take your time and test fit often, any mistakes here will show)

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. Step 8

.Using a spring clip to hold the two switch bezels together, test fit them in to the trim bezel, You will now be able to see just how much of the right side of the trim bezel (Which we left long in step 4) has to be trimmed off. Now trim the right side of the trim bezel down so the two switch bezels will fit snug (Again be care full not to take too much off because the snug fit is what holds the 2nd switch bezel in place.)

.The trim bezel should look something like pic #22, of the back and Pic #23 of the front. Notice the top, bottom, and right side of the switch bezel opening have bin trimmed to be even all the way around. It is important that you get all the edges even, straight, and smooth in order to obtain that factory installed look.

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.Step 9

.Ok now back out to the Jeep. Re-install the switches into the switch bezel and screw it back into place. Snap the center trim bezel back in place but do not put the screws in yet. Now you will need to take two measurements from the back of the trim bezel to the raised plastic on the right side behind the bezel. Take the first measurements in the upper right hand corner (image #26) and the second in the lower right hand corner (image #27) of the opening where the 2nd bezel will sit.

.Now using the line where the textured front meets the smooth side (Image # 28) as a starting point, transfer the measurements to the right hand side of the 2nd switch bezel. Mark a straight line between the two marks. (Image # 29) Cut the factory mounting edge off the switch bezel on your marks.

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. Step 10

.Remove the center trim bezel and test fit the 2nd switch bezel into place. The right edge should sit flush against the dash (image #30 & #31) and the top edges of both bezels should line up (image #32). While holding the 2nd switch bezel in place put the center trim bezel back on. If you have everything cut and trimmed just right the center trim bezel should be holding the 2nd switch bezel in place with a nice snug fit. If the center trim bezel does not fit back on just right you may need to trim it and /or the switch bezel to obtain a proper fit. If the 2nd switch bezel is loose and moves around you can use the end you cut off in steps #5 & #8 and some screws to make a bracket to hold it in place.

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. Step 11

.Once you are satisfied with the fit of the bezels, remove both the center trim and switch bezels. Install the switches and run the wiring. Now re-install the switch bezels, the center trim bezel, the two screws on top of the center trim bezel and the top vent trim.

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. Tips and Hints

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  • Take your time.
  • Check your measurements twice before cutting.
  • Test fit the parts together often.
  • Use fine and extra fine grades of sandpaper, disks, and drums. It will take more time and more effort on your part. But it’s worth it if you want that factory look.
  • Work on a towel or peace of carpet to help prevent the front of the bezels from getting scratched up.

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