How To Build Up Plastic??

[joeko23]

Hey guys I’m trying to incorporate a Mercedes dash with a Camaro center console and want to build up the bottom section of the dash so it transitions smoothly and almost seamlessly to the center console. Anyone know what material I need to do this besides fiberglass? I was thinking to use foam and sand/shape it but don’t know what foam or glue etc. any advice greatly appreciated!

[ProTouring442]

I'm thinking out loud here, but I *think* I would make the piece that goes between the console and the dash as a separate piece. I would probably make it from blue builder's foam, and cover it with fiberglass cloth and epoxy resin.

[andrewb70]

Damn, that is ambitious. I have no help to offer beyond that, but looking forward to reading what others have to say!

Andrew

[joeko23]

Thanks for the reply, I can’t make it as a separate piece because I plan to put an iPad in they big hole. Right now it’s about 2 inches too small so it as to be attached to the dash.

[jlcustomz]

https://www.polyvance.com/
I'm possibly the most knowledgeable idiot here about plastic fabrication, Having done both a 2010 & 2016 Camaro nose conversion to my el camino, as well as many other plastics related projects.
Not sure exactly what type of plastic that is, (abs hopefully), different plastics have different characteristics of what you can do with them . Some can be glued ,some glued or welded, more difficult plastics such as polypropylene, polyethelene , TEO, etc, can be plastic welded either by a hot air method involving rods or strips or direct contact welding, similar to solder guns. Many plastics can be shaped, reshaped with heat. At the least you would need the same type of donor material.
Some fillers can stick to some plastics. texture can be redone , but is difficult. There is also spray texture, sand entire part smooth & spray entire part. Interior parts can be repainted with spray adhesion promoter & interior spray paint such as SEM. Parts can also be covered with landeau (white sheet) foam to cover minor imperfections & wrapped with vinyl, leather , ultraleather etc.
Plastic type needs to be identified. Marking on backsides of most products, may find something on inside of glovebox. Also a parts search of new part for sale may tell you.
If it is abs, as I hope, you could either glue or weld. Homestores have abs glue in cans in plumbing sections, usually black. Anything new to you should be sampled with first.
An option could be fiber glassing over area with 2 part epoxy resin & cloth for the new parts.
So several options here, check around on the link to polyvance, The are the main plastic repair supplier. Get your thoughts together & get a better idea what route you think you want to go & I can further help as I love to see cool ambitious project actually get completed..
Joe.

[joeko23]

Happy New Year to everyone! So the dash is going to be recovered by a professional upholstery shop with vinyl or similar so I’m just looking for a general shape that the shop can just cover over. I’m thinking easiest is glue some foam to the plastic that I can easily shape. Then do fleece with resin or fiberglass with resin for strength. Just don’t know which type of foam to use and how to attach the foam to the plastic. Once foam is attached to plastic your recommendation whether to fleece resin fiberglass or just fiberglass and resin. There’s always option 2 of having the Upholstery shop do this. Just don’t like having to pay for something I can do. But if this is too difficult paying someone is definitely worth it. Plus I don’t want to ruin the dash or center console because I got a great deal on them and they are not too easy to come by.

Assuming this is ABS, I can’t use abs glue to glue plastic to foam right? The stuff at the Home store is for abs to abs.

[badbu68]

You could use some spray foam expanding insulation to it if you don't want to use rigid foam.

[andrewb70]

One suggestion I do have, is if you have a friend that can digital model this part for you, then you can have it 3D printed.

Andrew

[jlcustomz]

If you just want to do foam , get your basic great stuff spray foam & cover console & floor with plastic. Wipe lower part of dash with alcohol for adhesion,scuff with coarse sandpaper,& wipe again. Gradually spray foam & let start expanding & spray enough to grow bigger than needed & let dry. Spray foam will adhere to the plastic (& your skin if it touches it). Then you can cut foam with serrated kitchen knife & coarse sandpaper. Can spray a little more in spots afterwards if needed. Then you could get a quart kit of epoxy from marine store (such as west marine) & fiberglass cloth & cover just a little ways up the original part for strength. Next day can be sanded & regular quality bodyfiller can fill imperfections & resand. Would not use fleece. I said epoxy resin because of bonding strength rather than polyester, though you may get away with it. Most fiberglass matt won't dissolve in epoxy , which is why I said cloth.
Get a decent outer surface & interior shop will use contact adhesive to attach either thin sheet foam & fabric of choice or fabric only.

Abs glue is to abs only. Abs can be bought in small sheets & heated & bent, but a little higher skill level for most.
As previously mentioned, any step of project you've never done , you should do a small sample before proceeding.

What particular customization skills an upholstery shop may have varies, but I'd personally be pretty untrusting with most. Just sayin.....
EDIT, also cut your bigger hole first for screen.

[jlcustomz]

So, what Camaro are you putting this in?

[joeko23]

Going in or rather is already in a 69 Camaro. Dash is from a Mercedes CLA and console is from a 17’ Camaro. Btw the bottom of the dash is exactly the same width as the Camaro’s so it’s really a perfect accidental fit. Had to cut about 3-4 inches of front dash where defrost vents are. I really want a unique high end European style interior that’s actually functional. I don’t think I’ll be able to find a shop with the same vision as me so that’s why I’m tackling this myself. I will definitely try the spray foam technique with fiberglass. Right now I have a few more things to figure out before tackling this. Thanks for the info and I will definitely post pics when I do this. I also bought the guage cluster from the CLA and 4 1/2” guages from speedhut should fit perfectly along with 2 small 2 1/16” guages for temp and fuel will fit in the middle where the screen is.

[jlcustomz]

I agree not too many shops will have your vision. There are some but I've had no luck anytime I've tried to pay someone for anything. So screw em . DIY ,you got this far.
Did a little google search on fiberglass polyester resin to abs plastic & it is said to melt in & bond to abs, so polyester & fiberglass mat would be easier than epoxy & cloth to mess with.
When you get back to it, you can pm me if you'd like, I don't always check into this section often.

[joeko23]

Thanks for the input! Will post updates when I get cracking at his

[Deluxejoe]

I do this a lot by gluing on prototyping or precision board which sands down very easily and can be prometes or fiberglass after. I use 15 lbs. you can order it from mc master. Dm me if you need any pics

[jetmech442]

One suggestion I do have, is if you have a friend that can digital model this part for you, then you can have it 3D printed.

Andrew

Depending on your skill level, I'm with Andrew on 3D printing. I have very little skill making things symmetric when I foam/fiberglass stuff. I do have some CAD skillz though and Fusion360 makes it super easy. Using photogrammetry, you take about 15-25 pics of the console and dash installed in their final mounted position. Upload the pics to Fusion, and they create a mesh for you. Now you can create a perfect fit piece and have it 3D printed(1 click can upload the part to a 3D printer form Fusion). I fell in love with the 2107 Camaro shifter bezel when I saw it, so I used this process and am creating a custom console around that centerpiece.

I've been meaning to make a thread detailing the progress, just been falling behind.

Just trying to point out another path, hope this helps and good luck!