Squarebody Dash Repair -1st attempt

[EricU]

This is my first attempt at a Squarebody dash repair. After doing the usual “research” on different websites and University of Youtube, this is what I came up with.

The materials that I used were:
Canned spray foam
Hardware store mesh
TotalBoat’s FlexEpox (flexible epoxy) after seeing another post
Upol 7061 Flexible High Density Body Filler (Flexible Bumper Filler)
Upol Raptor liner

I pulled this dash out of a Suburban parts rig that I bought a while back. Pretty typical cracked dash, not as bad as some that I have seen.

Since this dash is going into a C30 dually that I am going to sell (I really don’t need two of them) I decided just to do away with the speaker cut outs. I also V-grooved out the various cracks

[EricU]

Bought some mesh material at the local hardware store along with a can of foam. Cut the mesh to size and glued them in place using CA glue.

The CA glue worked very well.

[EricU]

Foamed it up and left for the evening.

The next day I used a combo of blades and my little grinder with a 3” 30 grit disc to knock down the foam.

[EricU]

I had high hopes for the Upol 7061 Flexible High-Density Body Filler (Flexible Bumper Filler) and used it on one of the cracks that I had V’d out.

The Upol does sand easy, the problem was that it was too thick and therefore not flexible enough. The dried vinyl adjacent to the flexible bumper filler just cracked away. So I ground it out and used the TotalBoat’s FlexEpox, which did work quite well.

But don't throw away that tin of bumper filler as there is a use for it...

[EricU]

The flexible epoxy is good stuff but a little more difficult to work with as it has a pretty long setting time. It also stays somewhat viscous and moves around. I tried to level the surface as much as possible, but due to the shape of the dash I had to do it in two application.

The flexible epoxy is more difficult to sand. I used a combination of a sanding block and my DA

[EricU]

After a couple of coats of the epoxy, I went back to the flexible bumper body filler which spread out very nice.

At this point, if I was planning on covering the dash with either vinyl or leather, I would be done.

But this dash is going to get textured using thinned down bed liner, so I will be doing a bit more prep work.

[wixthedog]

Excellent work! I look forward to seeing how it turns out.

[ChevyMopar1969]

Looks good!

[EricU]

I didn’t like the corners that I had filled with the bumper filler as they were also cracking adjacent to the filler. So I ground them down and added more foam.

Cut the foam out the next day, ground it back some and added a skim coat of the flexible bumper epoxy.

[EricU]

I didn’t like the way the VIN window was turning out, so I made this little piece out of 1/8” acrylic that I had and used CA glue to install it.
It is a much cleaner look now.

[EricU]

A little more DA work with 220 then 320 and a good cleaning and I am FINALLY ready for texture and color.

[Mathew21]

Nice work, Thanks for sharing.

[Factory Guy]

Really nice job!

[kipps]

EricU, do you have any close up pics of the texture on that dash?

[EricU]

Originally Posted by kipps

EricU, do you have any close up pics of the texture on that dash?

I will get one when I start screwing it all back together.

I really like the texture as it is much more modern without looking out of place.

[57NAPCO]

Eric, I have a dash that I would allow you to practice your skills on

[EricU]

Originally Posted by 57NAPCO

Eric, I have a dash that I would allow you to practice your skills on

You pay the shipping and don't be in a hurry!!!!

If I were a kid, they would label me ADD.

[evan]

Good job! I'm looking forward to seeing it installed.

[dagnabbitt]

Lots of guys have attempted it, but that is the best dash repair I have ever seen. I am really blown away, I will never throw away a cracked old dash again without at least trying to get this result.