The first job is to make a template, so clamped a piece of mdf to mark the lower edge of the dash and measured down a fixed distance from the top edge over the full width. The mdf has vertical lines to ensure each measurement is vertical, (the transmission tunnel limits the template depth so I cannot capture the full width of the curve).
The template then has the dots joined up.
Transferred to a wider sheet. This may be the rear dash panel - I will see how strong it turns out.
Curve cut out.
Fits ok.
Drilled and bolted on.
Cut a small slot to trial fit the steering column, traced correct cutout.
About right - maybe a little larger.
Added a strengthening rib at the bottom that will also be rounded to 20mm radius for IVA - starting not to like this material!
Added a block of wood to take the switches - I do not like the way this is going, this is a car not a bookcase.
Tufnol sheet has arrived... Smooth, flat, beautiful precise engineering plastic... this is what cars are of made of today. Decided there is enough material to make both front and back so have abandoned mdf dash, which now becomes a template for the tufnol.
Coverd the tufnol with plastic for protection, can just get two sheets of the right size.
First cut in half - this is wonderful stuff to cut - first manufactured 70 years ago, still good today.
Marked out using the old mdf dash, starting to cut out, wood jigsaw blades work fine, but do get hot.
Fits great..drop section looks ok, I think.
Machined a 4mm radius to allow the dash to fit correctly, did notice it was easy to burn, so will bear this in mind when cutting the bottom edge which must be 20mm radius, this will need a big router cutter.
The bottom edge of the dash must be built up to provide enough material to allow the 20mm radius to be formed, I will use three layers of 10 mm mdf. These three, plus the two 5 mm tufnol layers make 40 mm.
Gluing the three sections of mdf together - back to woodworking, but this will cut better than tufnol.
Truing up the top edge using an edging cutter, the straight edge is thelarge sheet of mdf on the bottom.
The dash will be used to guide a router cutter to cut the mdf to the same profile, so this must be finished.
Bottom edge glued and screwed on.
Ready to trim the mdf. The router cutter has a ball race that will follow the edge of the tufnol and trim the mdf to the same profile.
Finished, one edge now.
Happy with this.
Fits in the car to.
This completes the rear panel.
