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How To: Fill the Centre Dash Pocket

14K views 28 replies 19 participants last post by  scoob  
#1 · (Edited by Moderator)
Since I ordered my air suspension, I wanted to place my switches on the dash somewhere. I have had switchbox's before, but hate having to keep them in my lap when I am driving. After looking around the dash, I figured I would fill the pocket right above the ashtray since I never use it anyway. If you have dual climate or navigation, you may not have this pocket. Here are some instructions on what I did:

1. First Take off the center console. Open up the ashtray and tug. This will require some force to get it free.

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2. Unplug all of the wiring harness'. There is one that you have to use a screwdriver to pull the orange safety tab away to get it off. It is circled below.

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3. I chose to take off the buttons near the vents so there would be no risk of damaging them, plus I will be driving the car while I work on this project. They were held on by (2) 5/32" screws. I was suprised to find that I did have a 5/32" socket in my toolbox. It will probably be the only time I use it.

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4. The climate controls are held on by (4) 5/32" screws, pictured below. Remove them and keep them in a safe place.

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5. Take out your dremmel and try to cut as close as you can to the edge. Be sure not to cut off the 2 clips on the bottom.

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6. Here is a pic with the pocked removed. I changed out the dremmel bit to a sander and smoothed out the edges.

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7. Take some sandpaper and scuff the area that we are about to fiberglass. This will help with adhesion.

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8. Take a piece of cardboard and make a template of the hole. Cut out the template and secure it to the back of the bezel.

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9. I put some saran wrap around the cardboard to make it easier to remove.

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Continued. . .
 
#2 · (Edited)
Part 2

10. Get out your fiberglass mat and precut your strips. You don't want to have to cut any more strips once you start playing with the resin. It gets very sticky.

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11. Mix up your resin. Red bull is optional, may be replaced by your favorite beer or coffee if you are doing this at 8 in the morning like I was.

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12. It's hard to tell in the pic, but lay down a coat of resin.

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13. Start laying down your fiberglass mat once piece at a time. Take your resin and brush it onto the fiberglass. Make sure to soak the mat completely.

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14. Keep building it up layer by layer and making sure to soak each layer with resin.

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Let it thouroughly dry. I let mine dry all day and overnight.


Next we will sand, put one more coat of fiberglass on, sand, primer, paint and install the switches. Stay tuned.
 
#3 · (Edited)
15. Here is some sanding after the first few coats of fiberglass.
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16. Apply some body filler, aka Bondo, to smooth out the surface. Repeat this step until everthing is smooth and blended. You may want to put a final coat of glaze on there to fill any pinholes.
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17. Apply some primer and paint to your desired color. Since we were installing some switches for the air suspension, we measured out the holes and drilled them.
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18. Here is the finished pic of the center bezel installed.
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#9 ·
Hey Steve, tight work as always..!
 
#11 ·
What brand and color did you use to match the factory silver color? Also, how has the paint held up under normal wear?
That was the hardest part. Not finding a matching color, but actually finding a paint that would stick. I tried 2 other brands before the final can. The other 2 would not dry even after a day, so I had to take some laquer thinner and scrape off the paint. I will have to see if I still have the can. I do remember it was a metallic. There are also a couple coats of clear coat on it. Paint has held up fine so far.
 
#20 ·
Awesome job and fantastic write up! Thanks for sharing! Your a lot braver than me.... I wouldn't want to try something like that!
 
#22 ·
Very nice Steve... looks just like OEM !!! :fing02:
 
#23 ·
Would the dakota monitor fit in this new area you created?

Just curious.

Have you thought about using rocker switches for looks?

Good job by the way.

Oh yeah, someone asked if they were momentary switches.

I would assume yes since just like hyrdraulics you have to lift/drop the suspension on demand. You can't just turn it on and expect it to stop on it's own without some kind of control.
 
#28 ·
I am Jonesing so bad to get my Magnum from the Dealer. Stupid re-calls! Stuff like this is making me drool with all the little ideas I have come up with.

VERY nice job!

JB