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lexan bubbles
Original Lexan bubbles are tinted and tough to see through at night, and they don't do a very good job at deflecting the wind.
Date: 03/16/2008
Views: 334
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dash 01
I purchased a new dash panel that comes without the tinted Lexan bubbles and the flat riser section that sits under them.
Date: 05/20/2008
Views: 262
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dash 02
Some tape was used to visualize the center of the 'hump', along with desired outer boundaries of the new windscreen.
Date: 05/20/2008
Views: 247
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dash 03
Additional tape was used to visualize the position of the new vertical backing plate, and a ruler was used to determine the height of the new Lexan piece.
Date: 05/20/2008
Views: 249
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dash 04
Several cardboard half-circles of varying sizes were used to judge what size looked best. I ended up choosing the size on the left.
Date: 05/20/2008
Views: 252
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dash 05
The dashboard was removed and a simple aluminum piece was welded up to add structure and stiffness to the new piece being created.
Date: 05/20/2008
Views: 237
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dash 06
Some alum foil was laid down, and the aluminum structural piece was positioned.
Date: 05/20/2008
Views: 221
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dash 07
The fiberglass resin and mat were applied.
Date: 05/20/2008
Views: 266
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dash 08
After several layers of resin and mat, the new dash hump insert was complete in its rough form.
Date: 05/20/2008
Views: 236
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dash 09
The edges were trimmed, and the piece was rough-sanded and given a coat of primer.
Date: 05/20/2008
Views: 238
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dash 10
Both newly fabricated fiberglass hump inserts were epoxied into place on the underside of the dashboard.
Date: 05/20/2008
Views: 227
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dash 11
I made a circle cutting jig so I could cut the lexan on my router table.
Date: 05/20/2008
Views: 222
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dash 12
A sharp carbide straight cutting bit did an outstanding job cutting the 1/4" Lexan. All edges were then sanded smooth, and the rear of the Lexan hanging below the dashboard was painted black on its backside.
Date: 05/20/2008
Views: 239
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dash 13
The newly-epoxied fiberglass pieces were painted. Thin closed-cell neoprene foam was applied to the edge of the dashboard, and the Lexan pieces were bolted in place.
Date: 05/20/2008
Views: 243
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dash 14
A view of the finished product. It will do a better job than the original curved tinted bubbles at deflecting the wind, reducing wind noise, and will also be easier to see through at night.
Date: 05/20/2008
Views: 334
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dash 15
A close-up view of the neoprene foam between the lexan and fiberglass. It will keep water, dust, and sand from getting between them.
Date: 05/20/2008
Views: 258
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dash 16
A close-up of the end result. The screws were powdercoated mirror black, and look great against the Lexan piece's black painted backside.
Date: 05/20/2008
Views: 380
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plastic polish
Impact by bugs, dust, and dirt wear the Lexan over time and Novus polish has worked great to restore it
Date: 03/16/2009
Views: 212
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