sickspeedmonte
+1y
I've got a fiberglass dash/console project going on right now with my SS. I modified the stock dash by cutting off parts I didn't like and re-shaping with 2 part marine pour foam. You can get 2 cu ft for like $20+shipping from US Composites. So I made forms and poured it and it sticks right to the dash, and then you just shape it with 80 grit.
I made a console form and poured the entire buck out of foam and shaped it to the way I want the final console to look. Next step is to cover it in body filler and give it the final shape. I'm kinda winging this, but I've found out that the regular Bondo from the corner parts store doesn't tend to work to well. It goes on pretty thick and heavy and takes a ton of sanding to get it smooth. I'm just going to use the rest to fill in low spots, then knock down the roughness and then get a skim coat filler for the final shape. Block it out so it doesn't turn out wavy, and then prime it, wet-sand it, maybe wax it, spray it with mold release, spray it with gel coat, lay the fiberglass, and then I'll have a mold for the dash and the console. Next you have to wetsand and buff the inside of the mold, get it perfect, spray release and gel coat again, and lay the glass for the actual part. So I'll end up with the final parts to go in the car, the molds to re-produce if I need/want to, and the bucks will end up in the dumpster. I should be able to mount the dash without having to cut out any of the underlying structure, as it only mounts in 3 places (besides the 4 in the defroster vents which should be easy)