Latest picts of '49 Ford Dash swap

[Nick]

Here's the original dash:
http://68.33.194.190/oval/Dash/dash1.jpg

So far I cut the dash into 7 pieces and rearranged and left out 2 of the pieces (D & F):
http://68.33.194.190/oval/Dash/dash%20plan.jpg
So when finished it should be arrange (by letter): A, C, B, E, G and D & F are now gone.

Parts A&C are welded already (but messed it up a little bit) and also finished shortening the glove box (removing part F). The glove box by itself was tricky, double skinned glove box cover plus the dash part itself so it was more like 3 parts in 1. So now I'm on one of the hardest part of the whole project, welding the speedo to the center. Hard because the center ribbed part is about half an inch higher and bigger when matching with the left side of the speedo and the top part where the speakers used to be is missing.

Here's how it looks currently in 3 remaining pieces left:
http://68.33.194.190/oval/Dash/dash%20step2.jpg

The speedo hole is HUGE, about the entire height of a stock VW dash. But I'm thinking of taking the stock VW speedo opening and grafting it onto that speedo so it'll be tapered inwards a bit and any VW speedo will fit with no modifications. So far it's been about 10 hours worth of work.

My first real welding project and so far pretty satisified. I've only had about 1 hour's worth of welding before tackling this project. So anyone scared in learning to weld it's not really all that tricky (but having alot of the right tools helps ALOT so add those extra tools to your budget). Alot of problem solving stuff you have to think of also but satisfying when you figure out a way around the problems. I'm hopeing by next weekend I can get it mostly finished inside the bug.

[Azure'67]

NICE! Playing with the layout is an extra unique touch, very cool!

[crack monkey]

nick that looks great

[vwfanatic]

nick....that's gonna be awesome!

[Roadster Cliff]

Nick It's lookin great man. This is a great project and the end result will be a one of a kind dash. Keep up the good work!
Cliff

[bugdust]

Lookin good. I'm a welder by trade and your makin' me proud style_emoticons/<#EMO_DIR#>/cry.gif :D

[Unkl Ian]

That is going to look like a million bux! style_emoticons/<#EMO_DIR#>/thumbsup.gif style_emoticons/<#EMO_DIR#>/thumbsup.gif

[G-man]

Man that is going to look cool style_emoticons/<#EMO_DIR#>/stoned.gif

[Nick]

Thanks for the replies guys, much appreciated coming from you guys.

I worked on it a little bit today and running into some major problems but I think I have a plan around it. The speedo "ribs" is ALOT thinner and lower (doesn't stick out as far) then the attaching part of the dash (part A&C). It's ALOT more then first realized (like a full inch thicker and higher) :( Let's put it this way, I have to cut the dash at least 3 more different places to make the lines of the ribs flow more smoothly. Hopefully it'll look right once finished.

[John Kelly]

Hi Nick,

That's an interesting project. Would it be easier to put section D back in the middle instead of B, and then make a new mount for the gauge from scratch? We could kick around a few ways to do that if you want to.

John www.ghiaspecialties.com

[Nick]

Thanks for the idea John, but too late, I already started cutting the left side. And I still don't know how to fabricate anything from scratch yet (especially something that seem complex like a gauge holder). Hopefully in a few months I'll learn a thing or two.

Well actually I have an idea. Make a round tappered hole from a thick piece of wood, then cut a hole at the sheet metal a few inches smaller in diameter then the wood's hole. Then hammer the metal into the hole. Right? Kind of style_emoticons/<#EMO_DIR#>/confused.gif I saw the custom motorcycle show at Discovery channel once (not Jesse James but another guy) and he was doing something similar.

[Nick]

Just a quick photoshop of what it could look like.
http://68.55.193.20/oval/Dash/test.jpg
The top ribbed part of the stock dash won't be there though. Makes me wish it was stainless and I can weld good enough to leave it bare. My last post on this until I finish her up.

[Steve]

Nick, that's gonna look great, my man! style_emoticons/<#EMO_DIR#>/thumbsup.gif

Ya know, a flapper wheel works magic on makin' welds look pretty.

Well, other people's welds... not necessarily mine. style_emoticons/<#EMO_DIR#>/funny.gif

[Azure'67]

Originally posted by Steve@Jan 4 2003, 10:02 PM
Nick, that's gonna look great, my man! style_emoticons/<#EMO_DIR#>/thumbsup.gif

Ya know, a flapper wheel works magic on makin' welds look pretty.

Well, other people's welds... not necessarily mine. style_emoticons/<#EMO_DIR#>/funny.gif
Discovered that today, built a new muffler dealy with the new welder. Turbo muffler is nice, much better than the duals.
Scrap Metal: free
Welder: present
Muffler:$15
Paint:present
Total:$15
Looks like one of them spiffy $100 muffler setups.

[awshields]

I have done the same on the muffler. I like to use an old stinger and cut it at the dia. of the pipe I am using for the curve to the muffler. I also like to use a 2 1/2" Turbo 2 made by Cherry Bomb, 16 bucks at the local auto parts, and a couple af J bends from Summit of Jegs. It sounds good wito out beeing too loud inside the car.

[John Kelly]

Hi Nick,

All I see is the infamous red X, but what you describe is called a hammerform. Usually you have the form that you hammer over, the metal, then a hammerform top. All three pieces are clamped tightly together, then you gradually hammer the flange over the form. A hammer form can be made from bondo, wood, aluminum, or steel, as well as other materials. You can use a rawhide mallet, a wood mallet or a corking tool. A corking( or caulking) tool is a piece of wood, steel, or aluminum that you hit with a hammer to drive the metal over the hammerform, kind of like hitting a punch or chissel. The corking tool can be shaped to fit the work more easily than a hammer, and is more controllable.

John www.ghiaspecialties.com

[Nick]

So I finally got back onto this project, I needed some time off from frustration. Here's the latest picts so far, just have to get the little holes and stuff welded up and figure out what to do with the radio plate in the center, should I match it up with the stock VW dip or make it flat.

2 pieces left (this is how I left it months ago)
http://68.33.194.190/oval/Dash/dash%20step3.jpg

All wleded up finally:
http://68.33.194.190/oval/Dash/dash%20step4.jpg
http://68.33.194.190/oval/Dash/dash%20step4b.jpg

I'll need a little filler to smooth some parts out. Some places I messed up and not 100% satisfied but I'll just ruin it some more if I try and fix it so going the filler route. Overall pretty satisfied for my first real welding project.

Next steps, cutup the stock dash and weld this in place. I'll probably be using the stock VW speedo housing to weld inside the new dash sppedo housing.

[PapaG]

Looking good Nick. I can't wait to see how you fit it in the bug.

[Unkl Ian]

<div class='quotetop'>QUOTE</div><div class='quotemain'>I'll probably be using the stock VW speedo housing to weld inside the new dash sppedo housing. [/b][/quote] You could cut around the stock VW speedo leaving enough material so it could be mounted in the new dash from behind.So if you didn't cut it exactly round,it wouldn't show.And you would have a nice edge detail from the stock Ford opening.
And if you had the room behind the dash,you could tunnel the speedo into the dash.Cut a stip of sheetmetal perhaps 2" wide and form into a cylinder to match the dia. of the Ford speedo.Weld in place from the back,and mount the VW speedo on the end of the cylinder.Stitch weld,and finish the inside corners with a fillet of body filler.

[Nick]

I was thinking of the same lines, have like a funnel from the new dash speedo size into the VW speedo size opening. Here's a pic of a stock speedo in the hole to give you an idea how BIGGER the hole is:
http://68.33.194.190/oval/Dash/speedo.jpg

I'm testing around ideas for the speedo as well, maybe using this mesh face plate, uncertain yet. Probal make some small pointers welded into the inner housing just to mark certain MPH. This is only a test speedo, I'll be doing a better job later.
http://68.33.194.190/oval/Dash/speedo2.jpg

[crack monkey]

nick - looking good man. i think it would be cool to fill the holes in the dash and attach any knobs and the ignition under the lip.
with the radio area i would match up the one from the original bug dash i think it would tie in perfectly

wait. weld the ashtray closed and put the wipers, lights and ignition in that area ....killer

[Ianvwsb73]

One comment, what's with the lump sticking out at the bottom? Looks misplaced. Otherwise, looks great. peace, -ian

[Nick]

That lump on the left side is the stock radio / ashtray area (or what's left of it so far). I'm not sure what to do there yet so I just left it as is for now. I may try and match it up with thr drop on the VW dash (it goes all the way to the front 'firewall' on the bug).

[vwfanatic]

sweeeet nick!

[ThrasherBill]

Looking good Nick!

ThrasheR

[Kafer_Mike]

Looks pretty good for a "first real welding project". I wish my welds looked that good... :angry:

[tommy-turtle]

looks good nick

[Dr.Freakinstien]

real nice Nick,that's "free refill" nice.Good job,keep-up the arts.

[bugdust]

Lookin good!!! style_emoticons/<#EMO_DIR#>/thumbsup.gif

[Steve]

Very nicely done, Nick. I like it! style_emoticons/<#EMO_DIR#>/thumbsup.gif

[Vee Dub Nut]

Wow, that looks nice, cant wait to see it in your car....

Adam

[Nick]

OK,a little setback. I knew why I never finished welding the dash comepletly before I took a break, but I forgot the reason. Well I found out why, I was going to weld the left half first then the right half so the length would be exactly what I needed it to be. Well now my dash is about 4 inches too long style_emoticons/<#EMO_DIR#>/yelling.gif So I cut it into 2 pieces again.

My bug is finally in it's project space and not in the neighborhood streets so I'll be working on it alot now. Here's test fitting the dash. They are sitting a little higher but you get the idea. Maybe tomorrow I'll start cutting the stock dash out.

http://68.33.194.190/oval/Dash/dash%20step5.jpg
http://68.33.194.190/oval/Dash/dash%20step5b.jpg
I'm not using that steering wheel, just placing it there to see how it'll look more complete.

[crack monkey]

nick that looks insane! you are gonna leave the little hump at the bottom of the stock dash right? i think i told you about my idea for that, i cant remember.

see even though i wasnt there i was able to help move the car with my mind.

so where did the kit car get moved to?

[JBUG]

Man that's cool, If it wasn't for me working so much on my own project I would drive on over to check her out in person. Maybe I can tell my soon to be that we are going shoppin at the Anapp. mall and then we can just take a wrong turn to your place?? style_emoticons/<#EMO_DIR#>/funny.gif

[Nick]

Thanks guys. If you wanna stop by wait for a few weeks if any. I'm about to start my marathon on working on my car so hopefully I'll see alot of major progress within this month. Maybe I can get it to a stage where I can take it to last BugOut this year (August) so you may see the car there if all goes well. I was actually at Annapolis today, about a 45 minutes drive.

As for the radio hump, I'm keeping it there. The new dash has a hump there too, I'm probably going to relocate it and match it to the VW hump. I'm guessing this will take a week to completely finish the installation, still need to make glove box, speedo housing, etc.... Seems like almost done but alot of the small stuff I still need to take care of. After this I can't wait until my next project for the car, I'm sure you guys will like that next step style_emoticons/<#EMO_DIR#>/smokin.gif

Oh, the kit got pushed to the top of the driveway style_emoticons/<#EMO_DIR#>/smilespin.gif