Finally My own custom dash!

[astglenn]

I figured that some folks might want to see how a dash design is created and then turns a nice clean sheet of Reynolds Aluminum into something useful to car junkies like us. I have built many dashes for FF Roadsters. Now it is my turn!

I have learned from some of the guys that I have done dashes for. Many have inspired me. With some luck, I will do them justice.

Here is my current SC layout. I have too much going on. Too many indicators and my layout totally sucked. I pretty much ruined the beautiful simplicity of the SC layout.

http://i124.photobucket.com/albums/p18/astglenn/DASH/iphonepics087.jpg

Here is my new layout on the CAD system. This is where we can do just about anything that someone can dream up. There are hard limits as to what can go where, due to structural interference issues with the chassis. Geometry is wide open. I am waiting for someone to bring me triangular gauges one day.

My layout is the basic SC platform with some adjustments. My ignition key is hidden. The balance of switches are Lucas toggles at the H pattern and one RF pull switch for the headlights. Indicators are all located at left side position and comprise 1. hi beam
2. Low Oil Pressure (15 psi switch) 3. Hi Oil Temp (230 degree switch)
http://i124.photobucket.com/albums/p18/astglenn/DASH/iphonepics089.jpg

6061 T-6 x .042" Sheet goes into the waterjet and the CAD file gets loaded into the cut computer as a DXF file.
http://i124.photobucket.com/albums/p18/astglenn/DASH/iphonepics092.jpg

Cut part gets placed onto digitizing table for some QC and hand fitting of the items that will be going into the dash. The glove box that you see is one of Alex's units.
http://i124.photobucket.com/albums/p18/astglenn/DASH/iphonepics088.jpg
http://i124.photobucket.com/albums/p18/astglenn/DASH/iphonepics093.jpg

That's it for now. The finish on this dash is going to be really tricky. I will only say that there is vac bagging involved. I wont spill the beans until I see if I screw it up first. I will post as I go.
Thanks for looking!

[Mustang Man]

Very nice! I've always wanted to play with one of those high pressure water pistols when I first saw them used on Overhaulin!

Mark

[efnfast]

Hope you've worked w/ cf before - I'm doing a few pieces myself and it's a real SOB to get a good quality finish.

Also hope you're either making a fiberglass mold of the dash and overlaying w/ cf, or doign 3 layers of plain weave cf - carbon can have bonding issues to aluminum ..... (not to mention it's pretty lame - see my "wonderful" NCPainter pieces)

[astglenn]

No carbon fabric here Alex. Not a huge fan of the carbon fabric look look. We use carbon composite quite often in our military / structural work. I am well and truly burnt on that look. Are you using a pre-preg, or are you doing a wet lay-up? Aluminum bonds fine. It is a modulus differential and resin issue. If you want some data, PM me mang.

Mark: Me too! The thing amazes me. I have cut 5" LONG DOWELS out of 5" induction hardened armor plate with it. Dowels had less than .003 taper. I tried drilling the plate to see how hard it was. It shook off cobalt, Titanium Nitride and pure carbide. The waterjet cut it at about 1/4 inch per min. Yeesh.

[efnfast]

Wet lay-up ..... I'm learning 1 thing - I hate cf, lol =)

Regarding bonding to aluminum, I thought that, over-time, carbon will de-laminate (regardless of epoxy used) from aluminum? Perhaps there are special resins that prevent this from happening?

Mmmmm, I assumed it was cf when you mentioned vacuum bagging - I can't think of what else involves bagging it? :confused:

[LuckyWinner]

Nice dash Brother!!! between your dash and your side pipes, Im pretty jelous. Cant wait to get to Cali and see it in person.

[astglenn]

Nice dash Brother!!! between your dash and your side pipes, Im pretty jelous. Cant wait to get to Cali and see it in person.

We will show you a proper return celebration. Where are you deployed?

[OregonDave]

Interesting glove box. I'm thinking of ditching the heater so I can install a glove box. The only issue is it looks really shallow - am I missing something or is it shallow because that's all that can be accomodated in the frame? Also, can you clarify who Alex is?

[astglenn]

Interesting glove box. I'm thinking of ditching the heater so I can install a glove box. The only issue is it looks really shallow - am I missing something or is it shallow because that's all that can be accomodated in the frame? Also, can you clarify who Alex is?

I believe that Alex makes the glove box in two depths. There is plenty of room forward. I believe this is a shallow one to allow additional clearance for heater, etc.
http://acroadsterinteriors.com/Index.html

I have just completed a CAD file for a machined aluminum door that will fit the Alex's bucket. That is what will be in this dash. It should be pretty nice.

[patpur]

Do you know how to do a "turned" aluminum dash? I think that would look really cool in a Cobra.

[3kcarbon]

Wet lay-up ..... I'm learning 1 thing - I hate cf, lol =)

Regarding bonding to aluminum, I thought that, over-time, carbon will de-laminate (regardless of epoxy used) from aluminum? Perhaps there are special resins that prevent this from happening?

Mmmmm, I assumed it was cf when you mentioned vacuum bagging - I can't think of what else involves bagging it? :confused:

It may be due to galvanic corrosion. At my work we always have a fiberglass barrier between carbon and metal even if its a bolt on cowling or part. We use Hysol ahesives to bond with, engineers figure all that out we just do it...

[astglenn]

It may be due to galvanic corrosion. At my work we always have a fiberglass barrier between carbon and metal even if its a bolt on cowling or part. We use Hysol ahesives to bond with, engineers figure all that out we just do it...

Long term maybe. I think the biggest contributing factor is what is known as "Cold as a well diggers ...." Canada Eh. Alex is going to condition the resins for a couple of days to get the material somewhere north of 70 degrees. That will help greatly to liberate the entrained air from mixing. A degassing roller (Porcupine roller) and he should be home free...Eh.

[Mikey_P]

Here is a pic of an engine turned dash.

http://i61.photobucket.com/albums/h77/pelletm/Cobra/Bodyfit012.jpg

[astglenn]

I have never done the finish Mikey P. I am pretty sure that I can get the CNC mill to do it though.

[astglenn]

Here is the vacu-form template for the vacu-press work. This is a piece of "structural" plastic. It is a 1/2" thick piece of Delrin.

http://i124.photobucket.com/albums/p18/astglenn/DASH/photo3.jpg

[Mikey_P]

Glen, I'll get a hold of you when I get closer to my dash. That one was .060

How do you plan on fastening the metal door? Will the attachment be able to be seen from the front?

I really like your work, I wish you were closer so I could watch!

[astglenn]

The attachment is with section of SS / precision, micro hinge (piano type) that will be attached to the floor of the box section. The boxes will be bonded to the rear of the dash panel with a structural polyurethane adhesive. I am waiting for the lock/latches now. They are SS units / trigger-push button style. What I am after is a complete dash package with some really high quality finishes and the glove box done and installed when it ships out of here. They will be available in three stock gauge configurations, several finishes, or plain metal for those that wish to do vinyl/leather.

Oh and apparently one "engine turned" Ball Burnished piece for Mikey P......... For the beating you took and your willingness to put a foot back into the irons, I'll be happy to do one for you.

[cwrandolph]

Another "engine turned" dash. Still in-progress

http://i153.photobucket.com/albums/s222/cwrandolph/Dash041308005-1.jpg

[stroked 6t5]

some very sweet looking dashes out there

[WAYNES WORLD]

As much as I like the vintage looking stuff it sure is nice to see some of the personal touches some of you add to your cars. Some real talent going on here.
Wayne

[David]

Looking great Glenn! I wont spill the beans, promise :D

David

[LuckyWinner]

We will show you a proper return celebration. Where are you deployed?

In Afghanistan with 10th MNT DIV, at a Combat Operating Post, to close for comfort!!!!

[ipsale]

Lucky Winner, we are all still thinking of you. Stay Safe!!

Rob

[astglenn]

Well after some turns between walnut burl, two redesigns of the wing ends of the dash and a complete re think on the glove box, here is the new dash.

I used .067" 6061 aluminum. It is MUCH stiffer. Due to its stiffness, I re cut the taper at the wing extensions and bent them in the brake. This makes installing the heavy gauge dash, super easy. It looks really good and tucks in nicely. I used a donated (Thanks Dr. John Pierce) Alex's shallow glove box and cut an aluminum door to fit it.

The finish is powder coat. There is a reflective base with a dark tinted clear. The metallic was placed into the clear. The edge fade is really nice and the color is a subtle gold that matches my ghost stripes. We played for most of the day with finishes. I decided to go off the beaten path with this one. What the heck. I make dashes for FF cars. Why not right? The more I look at this dash, the more I love it.

The back lights are red. Looks cool. I also installed LED foot well illumination, as well as hi temp / low oil pressure lights. The gauge layout is our standard SC, in the Autometer Cobra sizing.

I am ready to leave for the Huntington show at 0500 tomorrow morning. A few days of surfing, beach fishing and general getting ready. It's tough, but I am willing to step up!

Here it is!!

http://i124.photobucket.com/albums/p18/astglenn/DASH/photonewdash.jpg

[Fifty-Two]

Absolutely gorgeous Glenn! I can't believe that finish is a powder coat!

Seriously .... Wow!!!!!!!!!!!!! :cool:

[JGPierce]

Glenn, it looks fabulous! All along I'm thinking you're heading down the wood dash look. The powder coating has some cool subtle tones to it. Very classic.

The curve of the gauges and glovebox follow nicely.


John

[astglenn]

I am rapidly falling in love with the finish. It is very subtle, blends into the ghost stripes, but pops under specific angles and sun illumination. This was one of those experiments that went well!

I did lay up a Burl overlay. This is a high end veneer product. This was laminated in the vacuum press. It is unfinished as of yet. We are learning the techniques as we go. It will be pressure finished in a vacuum chamber to infuse the urethane finish completely through the veneer membrane. We shall see how it goes. Rob Anderson (Otis) has set the bar pretty high for veneer.

Another angle
http://i124.photobucket.com/albums/p18/astglenn/DASH/PCDash1.jpg

Burl lay-up
http://i124.photobucket.com/albums/p18/astglenn/DASH/Burldash2.jpg
http://i124.photobucket.com/albums/p18/astglenn/DASH/Burldash1.jpg

[Someday I Suppose]

Glenn, looks great, always cool to see someone do something a little different.

Tell us more about that steering wheel center cap.... :-)

[PhyrraM]

Looks Great! Just like it was always meant to be there.

[Indy14]

Very nice job. Looks great!

[astglenn]

Glenn, looks great, always cool to see someone do something a little different.

Tell us more about that steering wheel center cap.... :-)

I made a bunch of them on the lathe. I have some that are 3.300" and some that are 3.500". They have either a square shoulder or radius. If you want one, let me know.

[Someday I Suppose]

Glen, very cool, let me measure my wheel and I will drop you a note, its the older style, which I think is the smaller size, but I'll confirm.

I was thinking what design would look great on one, I know David just set up to do some design work on wheel spinner centers, the steering wheel insert could be a cool idea as well, and a nice upgrade over the FFR decal.



I made a bunch of them on the lathe. I have some that are 3.300" and some that are 3.500". They have either a square shoulder or radius. If you want one, let me know.

[astglenn]

Yes indeed. I was going to have David draw up a program to machine the image of a Lawyer with the head of a chicken as our logo. :) I am open to discussion!

[David]

Glenn, damn dude, that looks outstanding man! Very very nice! Looks perfect on your car with the black paint job.

Re Center caps... I have a CAM file for a pocketed AC logo that I did for my friend. Once we get some spare ergs, Im going to do a center for Glenn. I think it will look hot on the knockoffs and steering center. Ive been looking at doing round badgets as well. Kinda pays respect for the creators/roots of the cobra chassis and body shape.

David

[astglenn]

Glenn, damn dude, that looks outstanding man! Very very nice! Looks perfect on your car with the black paint job.

Re Center caps... I have a CAM file for a pocketed AC logo that I did for my friend. Once we get some spare ergs, Im going to do a center for Glenn. I think it will look hot on the knockoffs and steering center. Ive been looking at doing round badgets as well. Kinda pays respect for the creators/roots of the cobra chassis and body shape.

David

Thanks David! hey lets do some. I think John has the SC deal going. Lets load up the Fidal and crank some out. Can we plese run one set with my logo (Lawyer with chicken head) tribute to the sodomite. :)

[David]

Sure, lets brainstrorm on the perfect law chicken logo :D

David

[Someday I Suppose]

Glenn, I did a quick search, but oddly enough couldnt find any shareware logos of chicken headed lawyers... :-)

[astglenn]

Glenn, I did a quick search, but oddly enough couldnt find any shareware logos of chicken headed lawyers... :-)

This one may have to be a custom piece!

[riptide motorsport]

I have dash envy!!!!!!!!

[Someday I Suppose]

Think limited edition, serialized... then 40 years from now you can produce a bunch more and say they were originals.


This one may have to be a custom piece!

[astglenn]

Think limited edition, serialized... then 40 years from now you can produce a bunch more and say they were originals.

Hahahahahahahah!! No kidding! It is always sad when a guy lets his greed outweigh his talent.

[Someday I Suppose]

Personally I don't have all that much talent, so I go with what works. :-)


Hahahahahahahah!! No kidding! It is always sad when a guy lets his greed outweigh his talent.

BTW, once David figures out the AC logo on one, I'll be the first in line, or second or third, but will for sure go that route.

[astglenn]

Personally I don't have all that much talent, so I go with what works. :-)



BTW, once David figures out the AC logo on one, I'll be the first in line, or second or third, but will for sure go that route.

Me neither. That's why I mow Borden's lawn!

[otis]

Glenn,
I like the look of the piece of burled walnut you have. I has lots of character. Though the powder coat dash is stunning. Just wonder how hot to the touch it will get? Glenn you have put together some great pieces. BTW, still working on getting the car back from the header shop to fit your alternator bracket and see if it will work.

Hope you had a good time at the Huntington show.

Rob

[astglenn]

Hey thank's Doc! The 4x8 of veneer was close to $800.00. I almost choked. I can get 5 dashes out of a 4x8. I am super picky about the lay of the match lines, or I could get more. There are other species that are really neat as well. Some of the crotch woods (Maple, Poplar, Sepeale,) are really exotic. I am going to make some up when I return to work next week. You have the Burl dash that is the high bar. I would appreciate your critique of the completed goods. I may ship one to you for a close look. The vacuum press is complete and the vac chamber for finishing should be done soon.
The .067 aluminum is really stiff. There are no getting warm to the touch issues so far. I am really enjoying this dash. I really think the color of the dash, popping with the stripes, got me "Best paint" The paint on the car is excellent. Folks seem to really go crazy for the Gold Ghost Stripes. Two guys had their painters on the phone while they stood by the car.

I love it! Thanks to herman for this shot...
http://i124.photobucket.com/albums/p18/astglenn/bb1d212f.jpg

[289FIA_Cobra]

NP Glenn. When I see this picture, it's exactly the reason you should have won. It all comes together and much like a hologram, you only get the stripes at the right angle and lighting and then it's like "WHOA! THAT'S SO COOL!".

Now about the dash we talked about.... ;-)

[astglenn]

NP Glenn. When I see this picture, it's exactly the reason you should have won. It all comes together and much like a hologram, you only get the stripes at the right angle and lighting and then it's like "WHOA! THAT'S SO COOL!".

Now about the dash we talked about.... ;-)

Thank you!

No problem Herman. You let me know when you want to get some ideas going. Im right there for you man..

[Fifty-Two]

Wow!!!!! After seeing the whole package work together in that photo I have an even bigger appreciation for how cool that dash is!!!! Amazing work Glenn! :cool:

- John

[astglenn]

Wow!!!!! After seeing the whole package work together in that photo I have an even bigger appreciation for how cool that dash is!!!! Amazing work Glenn! :cool:

- John

Thank's john. It was really just one of those attempts that went well and ended up being a great combination. It was actually a last ditch effort at the end of the 9th, just before the show. There is a pretty good pile of .068" dashes in my shop that were cut in-place to get the final shape of the end wings. The color was the result of five test shots. It didn't work until we put the metallic in the clear and shot over a silver base, transparent gold then tinted clear. Then it still looked a bit wrong until the dash was turned vertical. Then it just worked. There is zero artistic talent here. Just try till it was right. I was actually about to tank the idea, just before the worm turned.

[David]

http://i124.photobucket.com/albums/p18/astglenn/bb1d212f.jpg

Damn Glenn... look at that dash with your stripes! That is just outstanding... Pure class man, pure class!

David

[astglenn]

Thank's David. We sure missed you and Mary out there. Next year, you will be ready with the new roadster.

[289FIA_Cobra]

Glenn, just thought about the glove box - you mounted it from behind; did you just use adhesive?
I haven't had time to think about the dash yet. Sometime this year I'll let you know.
My next immediate mod will be the drop-in boxes for the trunk!
BTW: Ray in Madera just dropped by yesterday to pickup the 2 ton press! I PM'd David so he could talk to Ray about "borrowing" it. :D