ideas for my fiberglass dash

[corax]

I've been tired of of looking at the cracked dash for awhile now. So yesterday I pulled the dash out and took the clinometer off so I could sell it (never really use it anyway). In the process of searching for a way to fix my cracked dash pad I read this thread (http://forum.ih8mud.com/60-series-wagons/409790-cracked-dash-pad-repair.html), which opened up my eyes to the possibility of fiberglassing the thing over. Then I did a bit more searching and found this thread (http://www.240sxforums.com/forums/do-yourself-section/90406-how-fiberglass-dash-walkthrough.html) which is only slightly more involved and includes modifying the original dash with gauge pods.

I'm thinking of 'glassing a single gauge pod in for my vacuum gauge over the left part of the nearly useless "pocket" that Toyota put on top.
http://i280.photobucket.com/albums/kk171/batardsalamano/FOR%20SALE/100_4367.jpg

So, opinion time - should I just eliminate the pocket and run the 'glass over top of it or try to build up the sides a bit and give it a lip so it can serve some useful purpose? Any other ideas or thoughts for the top of the dash?

[Crinale]

I dont have any ideas, but how much do you think ud sell the clinometer for? i might be interested..

[corax]

I dont have any ideas, but how much do you think ud sell the clinometer for? i might be interested..


here 'ya go, Ultimate Yoters get first crack then I'm posting on other boards. As I get tired looking at it sit in the house I'll get more negotiable ;)
http://www.ultimateyota.com/index.php?option=com_smf&Itemid=26&topic=9598.msg95047#msg95047

[corax]

Picked up some resin and fiberglass cloth for ~$20
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash04.jpg

Took the dremel to the a-pillar pod and then heat molded to it to fit the dash. Here it is glued in place with some precision bent "all thread" to build up the lip a bit
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash05.jpg

dash all wrapped up like a mummy. This was a bit of a pain as the cloth kept coming apart and I'd get long threads stuck to my hands. I used a few dabs of glue in key spots to hold it in place on the dash.
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash06.jpg

The first coat's done. Now I gotta let this dry then tomorrow it gets a second coat after some sanding.
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash10.jpg

[corax]

The fiberglass got sanded down with some 80 grit in a block, vent openings were cut out with a sharp razor and I knocked down the high spots in the first layer. Then I built up the edge around the pocket with some bondo just as it started to rain . . .
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash12.jpg

. . . so I let the bondo set for a bit and then went out to put on another layer. Unfortunately, the cloth in my second layer was kinda loose and started to fold and wrinkle when I applied the resin. I also mixed the resin too hot and it started to gel and harden before I could get it smoothed out :shake:. At least it's only sanding and a 3rd layer shouldn't hurt anything

[Obi..]

Just a thought, did you let the dash sit out in the sun at all before glassing it? Just a reminder to always try to do glasswork at around 55-65 for best bond and workability, and yeah, stop mixing things hot, I've had a cup go up in fumes and flames, funny but stupid too. ;)

Check out Greg's dash pad thread when time permits, he's "Green Truck" on Pirate.

[4x4mike]

Looking good. I've always wanted to play around with fiberglass but have always chicken'd out. Doesn't look all the hard, just time and patience.

[corax]

Just a thought, did you let the dash sit out in the sun at all before glassing it? Just a reminder to always try to do glasswork at around 55-65 for best bond and workability, and yeah, stop mixing things hot, I've had a cup go up in fumes and flames, funny but stupid too. ;)


Temperature isn't an issue, it's been mid to low 50's and partial overcast for the last few weeks. I think I was just in too much of a rush and squeezed too much hardener into the resin. Lesson learned and I cut out the bubble and folds yesterday so I can just make small patches to fill the mistakes



Looking good. I've always wanted to play around with fiberglass but have always chicken'd out. Doesn't look all the hard, just time and patience.


Yup, I'm really surprised I never tried working with fiberglass before. I'm thinking my next 'glass project might be a center console with provisions to stash the 2M radio - that'll probably be a little ways down the road though

[YotaFun]

This might be a good idea for us 3rd gen guys to be able to retrofit a 1st or second gen inclometer to look very factory

[corax]

After mixing the resin for the second layer too hot, I had a bunch of bubbles and folds in the dash where I couldn't get it to stick before it set. Somewhere in the midst of this, I asked Corey (Slacker) from Toyota Fiberglass for some advice and got this reply:

your best bet is not to use glue .. but have the dash on some good stands that position it properly . When you wet out the cloth , it will "sag" down , so remember that , and if you cant do it all at once , then don't .. let the first part cure , then move your project over and do the other piece .. you can do the layers all in pieces to get the best final outcome .. hope that makes sense.
It kinda sounds like I didn't really need to wrap it in one piece and just made the project more difficult for myself . . . live and learn

So I used a sharp razor to cut out the bubbles and folds. I cut up some of the scrap cloth that I had left over into "patches" that I could use to fill the craters that were left. I also mixed the resin much cooler this time, in fact it took nearly 5 hrs to fully cure this time around instead of the usual 1-2 hrs. While I was at it I added another layer to the bottom and sides of the dash pocket and wrapped a layer over the gauge pod. The remaining resin got brushed over the front and top of the dash with a little bit used to "seal" the edges around the vent openings

This morning (as soon as it stopped raining) I cut the frayed ends of fabric off and started sanding down all the patches. Here it is after the first coat of primer. I'm not done sanding and smoothing, but this will let me see where I need to work on yet. If I was flocking the dash it'd be done the way it sits since the flocking will cover bad sanding, but I'm painting it with Rustoleum Hammered finish so more sanding is in order.

http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash16.jpg

http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash15.jpg

http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash14.jpg

[corax]

I test fit the dash and found that certain areas had to be trimmed for it to fit properly - all of the trim work was done with a sharp utility knife which made things easier.

The screw holes and edges here . . .
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash17.jpg
. . . sit on here. See the plastic slot under the screw tab that the dash slides into? I had to sand the fiberglass just a hair thinner than it was to get it to slide in properly
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash18.jpg

the fiberglass that I originally had wrapped around was cut along this line so the dash will sit on the forward shelf properly
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash19.jpg
I also had to cut small notches for these clips . . .
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash20.jpg
. . . . which slide into the dash here
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash21.jpg

so now that I know the dash fits with the fiberglass on it, it gets one very thin coat of bondo to fill any pin holes or irregularities before final sanding and paint
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash22.jpg

[Small_words]

Keith. You Rock!!! I'm serious when I say you're my inspiration.

[corax]

Thanks - just kinda bored and unemployed at the moment, trying to find cheap projects to occupy my time
(how stir-crazy do you have to be to take FEMA online training courses just for $4its and giggles?)

[Seanz0rz]

those fema courses are actually pretty good. especially if your job includes safety and response to emergencies, even if those emergencies are small like an injured person. safety is a huge deal for companies

oh and i fricken love the dash. maybe ill try something like that on the vw.

[Small_words]

Two of my friends made the switch from trades to construction safety because they were bored and unemployed. Fewer safety directors than fitters. If you want to spice up your boredom viewing, enjoy OSHA.

http://www.oshacampus.com/

[DHC6twinotter]

Looks great Kieth! I've never done fiberglass work, but I've been contemplating a small project for my 3rd gen.

http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash21.jpg

How did you make that clip pocket?

[corax]

The clip pocket was already there on the metal frame of the dash, I just had to cut an opening for the clip would be able to slide into it

Give it a whirl. The materials aren't so expensive that you'd feel bad making a mess of something - $5 for 8 sq feet of cloth, $20 for 29 oz can of resin. It looks like a lot of people use 1/4 ply for a frame. Hi end speaker boxes are started with poly-fleece stretched over a frame and soaked with resin. There's plenty of opportunity to be creative. Case in point, my favorite custom center console (http://www.yotatech.com/f115/custom-cb-ipod-console-shifter-boot-upgrade-139770/) (and if I don't get hired soon, maybe my inspiration):
http://i274.photobucket.com/albums/jj277/TheQDog/100_0100.jpg

[corax]

On the 1st gen 4runner, the hardest thing about yanking the dash is taking out the far side passenger vent to get to one of the mounting bolts. One of the quick things I did to make dash removal later easier is break off the locking tab on the dash vents, spring tension from the clip will keep it in place anyway.
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash25.jpg

3 coats of Rustoleum Hammered and I slid it back into place. It's a bit glossier than I wanted, so I'm gonna live with it for now and I might respray it with dark grey interior paint later - otherwise, the color match came out pretty good

View from the driver's seat
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash26.jpg
Passenger's side
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash27.jpg

Since the vents sit recessed in the dash a bit I want to wait 2-3 days for the paint to completely cure before I put them in to avoid scratching the paint.

[Seanz0rz]

to keep the color, cover it with a matte clear coat. you will despise the gloss in a matter of minutes.

thats actually why i dont clean the dust off of mine, keeps the glare down!

nice work though, looks great!

[corax]

Cool, thanks for the tip about the clear coat. I'll pick up a can next time I run by a hardware store

[Obi..]

*Another trick with the clearcoat is to use that fleece you mentioned, spray a lighter than finishing coat on the glass and let it tack up, then lay the fleece on it for just a second and pull it right off, hopefully having no fuzz be allowed to stay behind. Let it harden up then go back with a seal coat.

It'll texturize the surface. :D

[corax]

Finished pics and I'm done messin' with it. I used some generic dark grey vinyl interior spray paint to knock the glare off. It's a near perfect color match and fits in well even though there's no texture to it.

http://img3.prosperent.com/images/250x250/shop.advanceautoparts.com/wcsstore/CVCatalogAssetStore/N3281/large/7141486_dpl_hvp111_pri_larg.jpg

http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash28.jpg
just gotta touch up the corner of the vent openings where the paint got scraped off pushing the vents in
http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash29.jpg

http://i280.photobucket.com/albums/kk171/batardsalamano/Dash/Dash30.jpg

[DHC6twinotter]

Looks great Keith!

[YotaFun]

Sweet