At 01:49 PM 12/10/2009, John Rodgers wrote:
>My question is - "Has anyone ever hardwired the  instrument pod in lieu
>of the dash foil?"

Since I'm a pedantic sonofagun I'll point out that the foil is the
actual copper in between the two layers of polyester in the
instrument panel flexible circuit. :)

It would be a stinker to wire up a complete one.  Much easier to use
an existing one as a template for a flexible-circuit maker like
various of these:
<http://www.google.com/search?q=flexible+circuits>.  The connectors
could be an issue but I very much doubt it would be insurmountable.

In addition, they're quite repairable by someone used to working with
them, either by soldering or by using a pen such as this:
<http://parts.digikey.com/1/parts/956981-conductive-pen-flex-circuit-3oz-cw2900.html>.

Perhaps it's the nomenclature error that has made them seem
mysterious?  If you google foils you won't get much help with flex-circuits....

>In time that dash foil is going to become a van killer if we don't find
>a replacement. I've got three vans - and sooner or later that foil will
>become an issue.

This is where I get confused, because this should be one of the most
durable parts of the van.  I don't understand why people are having
troubles with that flex-circuit unless they're abusing it in some
way.  It's strong, it's made of polyester (MylarTM) which is very
durable, and it sits well supported in a nice protected place doing
nothing, so what can happen to it?  The weak point is the LED
connectors and such that are crimped through the copper, but people
don't seem to be having trouble with them, so how are they getting
torn up?  Another weak point could be the adhesive between the
layers, I suppose.  Seriously, what happens to these things?  The
four or five that I've handled myself have all been in perfect
condition, as I would expect them to be.

Yours,
David