Custom Dash Build

[ZohanIsBack]

Finally took off the dash Saturday night and am starting to strip the car down to the firewall. I am removing the metal dash frame off the dash, and using that in the car to fabricate a custom fiberglass dash I intend to wrap in PVC leather. The ultimate goal is a dash that:

1. Looks modern (shooting for an RX8/WRX style instrument cluster)
   
2. Has space for 6 gauge pods (maybe five, we'll see)
   
3. Has double din for touchscreen.
   
4. Has upgraded, modern round vents
   
5. Is set back 1-3 inches compared to the existing dash
   
6. Can accommodate vacuum actuators for climate control
   

I've been planning this for about 2 years. Finally taking the plunge!

[CW240Z]

Good luck with the project, and as always take LOTS of pictures! I am in the process of wrapping a Datsun 620 dash with a simulated leather material.

Chase

[Carl Beck]

1. Is set back 1-3 inches compared to the existing dash
   
2. Can accommodate vacuum actuators for climate control
   

Sounds like a fun project - Does "set back" mean you plan to make the dash less thick/deep? To get better A/C in the car {bigger evaporators} - the Dash in the 280Z's was made deeper. Making the dash thinner wouldn't really give you more passenger/driver room - and it would make working on it later - just that much harder.

I'd also want to make all the gauges/instruments and lights easy to remove/reinstall from the front of the dash. I'd also use all electric actuators... I'd love to fit the entire A/C & Heater System out of our Kia Soul {or any of a number of modern small cars} - into a 240Z. Before you build that custom Dash - maybe you can consider making it easily accomidate some other Factory A/C system. One that people could go to the junk yard and remove -to transplant easily and at relatively low cost.

But that's just me.. Good luck with the project..

FWIW,

Carl B.

[ZohanIsBack]

Good luck with the project, and as always take LOTS of pictures! I am in the process of wrapping a Datsun 620 dash with a simulated leather material.

Chase

Oh sweet! Pictures??? You have a build thread?

Sounds like a fun project - Does "set back" mean you plan to make the dash less thick/deep? To get better A/C in the car {bigger evaporators} - the Dash in the 280Z's was made deeper. Making the dash thinner wouldn't really give you more passenger/driver room - and it would make working on it later - just that much harder.

I'd also want to make all the gauges/instruments and lights easy to remove/reinstall from the front of the dash. I'd also use all electric actuators... I'd love to fit the entire A/C & Heater System out of our Kia Soul {or any of a number of modern small cars} - into a 240Z. Before you build that custom Dash - maybe you can consider making it easily accomidate some other Factory A/C system. One that people could go to the junk yard and remove -to transplant easily and at relatively low cost.

But that's just me.. Good luck with the project..

FWIW,

Carl B.

I'm super stoked to get started on it.

As far as "set back," I mean I am actually moving the dash back toward the firewall an inch or two. The distance the dash sticks out now isn't conducive to pulling out the inverted center dash and making it more sloped. Plus, the deep speedo and tach gauges make it possible to push them back a little without worrying about space behind the dash in that area. Ultimately, making the dash "thinner" (pushing it back toward the firewall) may make the space in back of the dash less, but I intend to replace some of the larger, bulkier units with smaller, higher efficiency units (the air motor, air filter, actuator for climate controls, etc). Plus, I just can't pull the angles on the dash out without setting it back. If I did, the center dash would end up over the shifter area.

Electric actuators... Huh. That sounds like a good idea. What's the advantage to that over vacuum control? Less chance of vacuum leak problems? I was thinking about that on the way home from class after reading your post initially and thinking maybe electric wouldn't be so bad. Also the testing the custom fitment. If I and up producing the dash, users will have to heavily modify behind-the-dash components, but I do want plenty of space for the A/C components, whatever someone decided to put in. Thanks for the input, it's much appreciated. I need all the ideas I can get because once I get the mold formed, this thing is pretty much goes in stone.

[ZohanIsBack]

Got the dash sketch kinda finished. Planning to make the instrument cluster look more like a GTO dash like what you see below. The reason the sketch shows a weird center instrument cluster is because I have decided to use a RX-2N multifunction gauge from a motorcycle as the main gauge for RPM and speed. Has nice startup gauge sweep, and looks amazing. Of course, the dash will be flat in back and I'll cut it out after I finish it, that way I can mock-up gauges how I want before cutting out the spots for them in the fiberglass.

The design features 3 gauge pods reminiscent ever so slightly of the original design. Below are two bezel vents, and between those are the defrost, hazard, accessory buttons, maybe A/C, recirculation, and on/off button for the car computer, etc. This bar could also be modified to fit a status bar, if one so desired to do something like that. To the left of the driver are for turning the lights on, and maybe mirror control/cruise control if I choose to equip it.

Still thinking about the possibility of producing multiple copies of the dash for others wanting to modernize. With that in mind, what suggestions do you all have regarding my design? Why do you like/don't like? Again, instrument cluster will be modified more than what's on paper, but the general idea?

Edited December 12, 2012 by ZohanIsBack

[Zedyone_kenobi]

Thsi is going to be great to watch!!!

You have my interest!

[72 OJ]

Me 2 ,,,,,,,,,, keep us informed

[ZohanIsBack]

Starting welding and modifying the general shape of the dash frame. Dang.... Looks so different and good with modern curves. Will post pics soon!

In the meantime, I need opinions. Would you sacrifice a glove box for better dash styling lines, or is a glove box necessary in a dash? If I did include it in the dash, it would be pretty small, but it might be possible to get everything I want in a dash. So torn at the moment. .

[psdenno]

Where do you plan to stash your gloves, registration, proof of insurance, spare fuses, maps, owners manual, and gas receipts without a glove box?

Dennis

[72 OJ]

Where do you plan to stash your gloves, registration, proof of insurance, spare fuses, maps, owners manual, and gas receipts without a glove box?

Dennis

Console box, plenty room for registration/proof of insurance/etc,,,,,:bulb:

[ZohanIsBack]

Hey all, just threw this on HybridZ, too. Finally got pictures and video of the dash build. So far looks pretty good. I have deleted the glove box for now. Because of the curve of the dash, I will need to add it back in after I have already finished the plug and mold and have dash off the mold. The curvature is too crazy at this point. Plus....I am not sure I actually want to add it in at this point because the dash looks amazing without it. And with the curves, I will have to make the door pretty thick and with special hinges to open, so it would be better to do it on a pull from the mold rather than the mold/plug itself. Great thing about fiberglass is the ability to add stuff in later.

Edited December 19, 2012 by ZohanIsBack

[ZohanIsBack]

I posted this a day earlier on Hybrid Z because it was the middle of last night, but here it is for you guys now.

Basically copied the driver side dash end near the door exactly the same as the passenger side. But it wraps smoothly into the gauge cluster area and finished on top. The design will make the right side of the dash cluster stick out less near the bottom right because it molds into the center dash area smoothly. Unless you guys think this is a big mistake, in which case some foam and more metal can remedy it. I just felt like a unique, more styled curve near the center dash part of the cluster would make the center dash feel more uniform, but of course, at the expense of symmetry in the gauge cluster . I figure it's a small price to pay, and really gives the dash a uniqueness. Look close at the pics near the end and tell me what you think. Cheers!

Overview of the dash on the driver side all cut out.

Starting to cut out the instrument cluster. Notice on subsequent images that the lines marked with a sharpie are not actually a fair representation of the gauge size since they are outlines. Since I will be foaming and smoothing the cluster panel and the walls are bowed out, I will bring the final surface closer to the driver, thus making the total panel size larger.

Finally installed in the car. Welded in temporarily. It was a little crooked. >_< Foam and resin, baby!