Custom Dash Build

[ZohanIsBack]

Boom! Driver side panel left of gauge cluster almost done. Space for buttons, and the shroud over the cluster in place to provide a rough base for the foam shroud to follow. Notice on the right side of the shroud/arch thingy that it needs to be cut. This is due to the fact that the dash actually forms a semi circle around the occupants. The gauge panel was welded in at a 90 degree angle (ha.....or thereabouts) to the driver. The shroud was welded in parallel with the panel. But the dash angle as you move toward the center is AWAY from the driver and toward the firewall. So I had to trim down the shroud down on the right to make it meet the left side of the center dash better. See following pics for this.

ONE OF MY FAVORITE SHOTS. Really shows the unique curve we through in with the dash. Starts inverted at a negative angle, then ends up positively angles near the middle. Wow!

Shroud Comparison 1. Here is what I'm talking about below in regards to making the right side of the shroud end up further toward the firewall than the left. In this picture it is symmetrical, but look at the angle needed to meet the center dash! It would be nearly impossible to do this and make it look good.

Edited December 26, 2012 by ZohanIsBack

[ZohanIsBack]

Shroud Comparison 2. Here is where it is finally trimmed and a mock-up made from cardboard is installed. The right side of the cluster shroud is now trimmed further toward the firewall, making the gauge cluster shroud unsymmetrical, but ultimately making the center dash more symmetrical and reducing the need for a crazy angle to meet the right side shroud with the left side center dash. , that was a mouthful.

Looking pretty darn good, in my opinion.

Ugg... Cardboard looks like crap from this angle. They'll be a lot of foam filling in the left side of the shroud curve. Don't worry, .

Edited December 26, 2012 by ZohanIsBack

[ZohanIsBack]

Shroud Comparison 3. NICE! Love this shot. Really shows the angle cutout on the right side cluster shroud.

That's it guys, let me know what you think. I was gonna post a video of me grinding down the frame in prep for the shroud, but it was just too long and boring.

End Addition. , I could see a few users watching as I uploaded to the last few posts. Sorry for the wait. The inline insert is kinda dumb and inserts images out of order, so I have to drag them back in order. should start using photobucket. :-/ Enjoy guys and Merry Christmas!

Edited December 26, 2012 by ZohanIsBack

[hr369]

mercedes dash looks similar i.e. the rounded instrument cluster

[ZohanIsBack]

Whoa! Yes it does, but I really wanted to go out there as far as the passenger dash and center console does. The 240sx also has a rounded instrument cluster, as do many 90s cars, but they're either hard to adapt or don't have the modern curves. This dash should be clearly set very apart from other dashes, and better yet, will bolt right in. But yes...takes a lot of work.

Are you working on a mercedes dash swap-in right now?

[hr369]

Whoa! Yes it does, but I really wanted to go out there as far as the passenger dash and center console does. The 240sx also has a rounded instrument cluster, as do many 90s cars, but they're either hard to adapt or don't have the modern curves. This dash should be clearly set very apart from other dashes, and better yet, will bolt right in. But yes...takes a lot of work.

Are you working on a mercedes dash swap-in right now?

No, its not my project. I just stole someone's dash swap pics off the net. This 200sx dash swap looks like the old z dash with the 3 gauge pod on top but more modern. It looks like they cut off the ends. Probably a real pita putting ends on that one. It was done in oz if I remember correctly.

I do like the addition of the airbag with the more modern dashes. The 200sx heating and a/c unit looks close to the 280z unit doesn't it?

I applaud your efforts. This is one area that doesn't usually get much modification and there is lots of room for improvement in these old

dash's design.

[ZohanIsBack]

Oh sweet, that looks great! Yeah the heating component does look really similar. This dash opens up so much space in the dash I believe I will be forced to modify a much more modern heating and A/C unit. Might have to pull one out of those smart cars, Ha! Actually, hoping to go with a GTO or infiniti A/C and heating if it will fit. I would love to fit an airbag in the dash and steering wheel, but I'll be upgrading to a racing wheel and my car will have a full roll cage, so the harness should keep me inside....hopefully, .

But thank you! These old dashes just don't fit with the sexy lines these cars have when modded with kits to make them more modern (think Twisted Sixx on TunerZine). Needed a big face lift, so I figure I would give it a try and maybe keep a mold I could reproduce the parts from for others. I have more pictures, I just need to get them uploaded. Probably this evening.

[ZohanIsBack]

So what I finished doing was the right side of the instrument cluster and the center dash. I really don't like how the right side of the cluster turned out because it looks like a dent, so I am going to go ahead and foam in that area and level it off close to the center dash curve. The dash is now out of the car, as you will see in later pics. It came right out with no problems, even after all that welding.

I bought in preparation for foaming and fiberglassing the mold:

• Two part urethane foam
  
• Release wax
  
• PVA
  
• 1.5 and 2 oz fiberglass
  
• Fiberglass roller
  
• 2" ABS for gauges
  
• Polyester resin
  
• Hardener
  

And here are the pics of what's been done.

Center panel installed for a test run of what it will look like and maybe what the general curve will be.

Ugg, that dent I "made" on the right side of the cluser looks bad. Definitely going to be using a lot of foam to level it out with the left side of the center dash.

Might be able to actually fit this center console in here, maybe....

Edited December 28, 2012 by ZohanIsBack

[ZohanIsBack]

Testing a rough S shape for the center dash. Decided I didn't like it as much as a concave curve many of the newer and modern dashes have. An S shape would be amazing, but would have require more thought into how the shifter it placed and a harsher initial curve right off the dash.

This stuff is amazing. I filled each little cup with about 2 mm of the liquid, then combined them. It is "cold" here in SoCal, so it only expanded about 20x, but still was very impressive. Hardens to workable in about 30 minutes. This was basically a test to see if the foam actually sticks to metal. Strangely, it broke away from the cardboard pretty easily. Just a few good tugs. But getting that metal piece off, even after trimming the foam wrapped around the edge, was nearly impossible. I believe I can pour it right on the dash.

Tranny tunnel trim tacked up and center console fit over it. I do believe that with some trimming, the center console will work with this design. For myself, I intend to redesign the center console with cup holders.

Without the console in place. Looks pretty rough with the box edges, but nothing a little foam won't take care of!

Yup, out of the car again already! Stands up nicely and came right out without any problems. Mounting points were well preserved.

Edited December 28, 2012 by ZohanIsBack

[ZohanIsBack]

Used a wire wheel over the entire dash to clear out welding slag and roughen up the metal further for foam placement tomorrow. Looking pretty good. I like the brushed look.

And some youtube vids:

Edited December 28, 2012 by ZohanIsBack

[ZohanIsBack]

Started foaming the dash. Here are the results and pictures.

And a video.

[psdenno]

Looks good! Thanks for the step by step pictures and video.

Dennis