Installation And Finishing Of A Fiberglass Dashboard For Weight Reduction

So, you're thinking about swapping out your factory dashboard for a fiberglass one to shave some weight? Great idea! Fiberglass dashboards offer a significant weight reduction, which can translate to better acceleration, braking, and overall handling. But, as with any modification, it's crucial to understand the process involved and potential pitfalls to ensure a successful installation and a professional-looking finish. This article will walk you through the steps, offering practical tips and insights along the way.

Understanding the Challenge and Benefits

Before we dive into the installation process, let's briefly discuss the advantages and disadvantages of using a fiberglass dashboard. The primary benefit, as we mentioned, is weight reduction. A fiberglass dashboard can weigh significantly less than its stock counterpart, sometimes reducing weight by 50% or more. This is especially beneficial for track cars, race cars, or anyone looking to optimize performance. However, fiberglass dashboards often lack the same level of fit and finish as factory units. They may require some modifications and adjustments to achieve a perfect fit, and the surface usually needs preparation and painting to achieve a desirable aesthetic.

Preparation: Gathering Tools and Materials

Proper preparation is key to a successful installation. Here's a list of tools and materials you'll likely need:

• Safety Gear: Safety glasses, gloves, and a respirator mask (especially when sanding).
• Hand Tools: Screwdrivers (various sizes, including Phillips and flathead), socket set, wrenches, pliers, wire strippers, crimpers, and a trim removal tool.
• Power Tools: Drill with various drill bits, angle grinder (with a cutting wheel and sanding disc), and a power sander (orbital or random orbital).
• Measuring Tools: Tape measure, ruler, and possibly a level.
• Cutting Tools: Utility knife, jigsaw, and potentially a Dremel tool for fine trimming.
• Fasteners: Screws, bolts, washers, nuts, and potentially rivets (depending on the mounting method).
• Adhesives: Epoxy resin or fiberglass adhesive (for repairs or modifications), and possibly contact cement for attaching trim pieces.
• Finishing Materials: Body filler (bondo), sandpaper (various grits), primer, paint, clear coat, and masking tape.
• Wiring Supplies: Wire connectors, heat shrink tubing, and a multimeter.
• Cleaning Supplies: Degreaser, wax and grease remover, and clean rags.

The cost of these tools and materials can vary widely depending on the quality and brand you choose. Expect to spend anywhere from $100 to $500+ depending on what you already own. The fiberglass dashboard itself can range from $200 to $1000+, depending on the make, model, and quality.

Step-by-Step Installation Guide

Here’s a general guide to installing your fiberglass dashboard. Always consult the manufacturer's instructions for your specific dashboard, as variations exist.

Step 1: Removing the Old Dashboard

This is often the most time-consuming part. Start by disconnecting the negative terminal of your battery. This is crucial for preventing electrical shorts. Next, carefully remove all the trim pieces, screws, and fasteners holding the old dashboard in place. Pay close attention to the wiring harnesses and connectors. Label them clearly to avoid confusion during reassembly. Take photos of the wiring and component locations before removing them – this will be invaluable later. Disconnect any gauges, switches, or vents that are attached to the dashboard. Be gentle and avoid forcing anything. Refer to your vehicle's service manual for specific instructions on dashboard removal.

Step 2: Test Fitting the Fiberglass Dashboard

Before you start making any modifications, it's essential to test fit the new fiberglass dashboard. Place it in the vehicle and check for proper alignment. You'll likely find areas that need trimming or adjustment. This is where patience is key. Use a marker to identify areas that need modification. Remember to only remove small amounts of material at a time to avoid over-cutting.

Step 3: Modifying and Trimming

Use a jigsaw or Dremel tool to trim the fiberglass dashboard as needed. Wear a respirator mask during this process to avoid inhaling fiberglass dust. Smooth the edges with sandpaper after trimming. If you need to fill any gaps or imperfections, use body filler. Apply the filler in thin layers, allowing it to dry completely between coats. Sand the filler smooth after each coat. Take your time and aim for a seamless finish.

Step 4: Wiring and Component Installation

Now, transfer the wiring harnesses, gauges, switches, and vents to the new fiberglass dashboard. Use your photos and labels as a guide. Connect the wiring harnesses carefully, ensuring that all connections are secure. Use wire connectors and heat shrink tubing to protect the connections. If you're installing new gauges or switches, follow the manufacturer's instructions carefully. Test all electrical components before proceeding to the next step.

Step 5: Mounting the Dashboard

Secure the fiberglass dashboard to the vehicle using screws, bolts, or rivets. Make sure the dashboard is properly aligned and securely fastened. Use washers to prevent the fasteners from damaging the fiberglass. If necessary, use adhesive to reinforce the mounting points. Double-check that everything is securely fastened before moving on.

Step 6: Finishing and Painting

Prepare the surface of the fiberglass dashboard for painting. Start by cleaning it with a degreaser and wax and grease remover. Then, sand the surface with fine-grit sandpaper to create a smooth finish. Apply a coat of primer and let it dry completely. Sand the primer lightly before applying the paint. Apply several thin coats of paint, allowing each coat to dry completely before applying the next. Finally, apply a clear coat to protect the paint and give it a glossy finish. Mask off any areas you don't want to paint, such as gauge faces or switches.

Tips for a Professional Finish

Potential Problems and Solutions

Approximate Repair Costs

If you encounter problems during the installation process, here are some approximate repair costs you might expect:

These are just estimates, and the actual cost may vary depending on your location and the specific shop you choose.

Conclusion

Installing a fiberglass dashboard for weight reduction can be a rewarding project, but it's essential to approach it with the right knowledge and preparation. By following these steps and tips, you can achieve a professional-looking finish and enjoy the benefits of a lighter, more performance-oriented vehicle. Remember to prioritize safety, take your time, and don't hesitate to seek professional help if needed. Good luck with your project!