Custom Dash Build

[ZohanIsBack]

Thanks! Yeah I want people to really see how the dash is coming together and how I did it. These dashes are pretty hard to turn out compared to other car parts. Many intricate corners and curves, but I welcome ideas on how to do it better and design ideas. One guy on HybridZ says I should add a passenger handle like the Lambos. Definitely something I'll consider once I have the mold and can turn out dashes to modify.

On that note, for any fiberglass buffs, I'm making a three gauge pod cluster just like the 370z above the center dash. Should I incorporate it into my plug and mold, or just make it once I pop a dash out of the mold?

Thanks!

[psdenno]

If you're "hand laying" the fiberglass, it may be easier to make the three gauge cluster as an add on piece. At least it would be if I were making the dash. Your skills may be far superior to mine, however.

Dennis

[ZohanIsBack]

Ok, good to know. I think I'll do that. Are you kidding? This is actually my first fiberglass project ever. No seriously...that's not a joke. It's like making enchiladas though, right? That was a joke... .

[psdenno]

Not trying to take this thread in another direction, but..........

The dash from the Ferrari 250 kit car that uses the Z as a platform has an interesting instrument layout. I wonder if that dash is available for purchase without having to buy the entire kit. Obviously, it fits into a Z quite nicely.

Here's link. Scroll down the page to see pictures of the pseudo-Ferrari dash in a Z.

http://www.carreracoachwerks.com/250-gto/

Dennis

[ZohanIsBack]

Psdenno, no you're fine. I like that dash a lot, but unlike the dash I am building, it still doesn't feel modern enough (more like a cross between a racing aluminum dash and the old style). And the one which is shown to be mainly fiberglass follows the older lines even more closely. The whole point of the dash I am building is to literally bring the car's interior into spec with a 2012 Mazda, Suburu, or Infiniti dash. This is extremely important to me and the person helping, so we will stop at nothing to push it all the way to the edge of modern styling.

[ZohanIsBack]

Hi all! Here are some updates on the dash. I apologize for the delay. I went ahead and have been doing work on the dash without doing updates. Medical school just started again today, so I am stretched for time like crazy now. With my BMW project done and my buddy back from break, we'll try to work hard on it over the weekends. Just not going to happen that much during the week as I need to study. Here's where we are now:

• I finished foaming the entire thing
  
• I shaved and sanded the foam to shape
  
• Jon (fellow student) and I started applying bondo and finishing the last shapes
  
• We poured a little extra foam over the instrument hood because it was just gonna be too much bondo.
  

And the pictures and videos from what you saw last until tonight:

Starting to pour the center part of the dash. This was actually the most fun in my opinion because it transformed the dash so much...

Edited January 8, 2013 by ZohanIsBack

[ZohanIsBack]

Plastic piece leftover after the pour. The cardboard is what I use to keep the foam from expanding really think, and instead expand vertically. The foam actually exerts quite a lot of pressure, and when pouring this stuff in pontoons, they have to cut relief holes to keep it from damaging the pontoons.

A little behind the scenes sneak peek at what the metal work looks like. So glad that is done!

A heating technique to preheat the metal, then keep the foam warm for maximum expansion and curing speed. It's amazing the difference heat makes. I wasted so much of this stuff by not knowing how to pour it correctly the first few pours. By the time I got to this part, I was spot on pretty much every time.

Edited January 8, 2013 by ZohanIsBack

[ZohanIsBack]

Left side of instrument cluster foamed in. End caps of the dash all foamed.

First pass sanding. Final shape on the passenger side pretty much all set. I'm very pleased with the way this turned out. Driver side still needs tons of work. I like the curves from the center dash to the bottom passenger side and will attempt to mirror (though at a higher level) on the driver side.

Side views

Closeup of the center. Needs some body filler.

Edited January 8, 2013 by ZohanIsBack

[ZohanIsBack]

Here's the good stuff! Body filler going on last night and tonight (technically also last night since its now past midnight. . .) .

Second pass sanding the end caps. Still a little tight in the car. Might go down another few mm on each side. More foam added to the top of the hood to shape it better.

That's all guys! More updates by this weekend!

Edited January 8, 2013 by ZohanIsBack

[ZohanIsBack]

So sorry for the slow updates guys! Medical school is back in full swing, and we're working our butts off again. I didn't get to the dash last weekend, but I WILL be doing more to it tomorrow for SURE! May not be huge steps, but we'll see what I can crank out. I've been building a rotisserie for the datsun, so of course that takes time, too. The main problem we're having is the fact that the dash is technically below the window trim in the center. We wanted a v shaped look to it both from the top and front, which is what we did, but unfortunately now we have to built a small extension running across the dash. It will be a "bar" basically that covers the window seal and finishes off the look of the car. Not to fear, many cars have these, including the RX8 I'm modeling it after. I just didn't think it would be necessary. But...I was wrong. Here is a picture of what one of these bars might look like:

Now, on to the good stuff. I did get the dash gauge cluster formed and it FINALLY test fit in the car. Tell me what you guys think. More bondo to come!

[ZohanIsBack]

Sorry for the delay guys. School took top priority up until about two weeks ago, so I had to lay this project aside for a bit. Kinda the story of my life, . Plan is to have the plug done this weekend and reverse mold within a few weeks. From there I need to make the gauge pod, then it's done. Here are a few more picture updates and a video update!

The main thing I did in the last 4-5 days was added more bondo and started sanding like crazy on it. It's starting to come together pretty good now, actually. Just filling on where I cut the foam too much (ugg) and sanding down where I had too much. Then sanding the bondo coats and getting it as perfect as possible.

[ZohanIsBack]

Alright guys, I got the pics from last night pulled off and another video put up. The entire dash has bondo on it. The corners and the transition line to the passenger side dash are not complete. As I mentioned, I decided against the symmetry on either side of the center dash when it comes to the lines, in favor of asmmetry which I felt ties the center dash and gauge cluster together. Making a "V" out of the center dash sides would have been cool, but in the end I think this will also give more styling options.

Here's what I had in mind for the center:

Here is what it ultimately ended up as:

Here are the rest of the pictures:

Pretty good so far here. The gauge shroud is the bane of my existence, but Jon did a good job laying the bondo. One more layer and a good sand and it should be pretty close. *fingers crossed*