Omar Khalid
Fiberglass is a popular material for dashboards because it can be moulded to accommodate various components, such as monitors, speakers, and stereo decks. It is also used to repair old and brittle dashboards, giving them a new lease of life. To fiberglass a plastic dashboard, you will need a range of materials, including resin, hardener, and fleece fabric. The process involves mixing the resin with the hardener, applying it to the dashboard, and then covering it with fleece fabric. Several coats of the resin mixture are applied, and the final product is sanded down to achieve a smooth finish. While it can be a time-consuming and challenging process, it is possible to create a functional and aesthetically pleasing fiberglass dashboard with the right tools and techniques.
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What You'll Learn
Prepare the plastic dash
To prepare a plastic dash for fibreglassing, you must first uninstall your dashboard and remove the upholstery, bolts, glove compartment, ashtrays, and everything else attached to the dash. You may also need to remove the vinyl coating, depending on whether you want to apply resin directly to the foam or not.
Before applying resin, it is important to test whether the resin and plastic base are compatible. You can do this by applying a small amount of resin to the back of the dash. If they are compatible, you can proceed with the fibreglassing process.
If you are using a mould, create a cardboard template for the top panel and one for the face of the dash, using the old dash panel as a pattern. Cut your sheet of fibreglass according to these patterns.
If you are not using a mould, you can simply lay a piece of fleece over the dash and cut around it. Secure the fleece to the dash with glue or a staple gun, making sure to staple on the inside of the dash so as not to damage the outer area.
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Mix resin and hardener
Mixing resin and hardener is a crucial step in the process of fibreglassing a plastic dash. Here are some detailed instructions and tips to help you mix these components effectively:
Firstly, it is important to note that the ratio of resin to hardener can vary depending on factors such as temperature, humidity, and the specific products used. Therefore, always refer to the manufacturer's instructions for the correct ratio and mixing procedures. It is also recommended to start with a lower ratio of hardener to resin in warmer temperatures.
When mixing, use a small to medium-sized bowl and combine the resin and hardener solution that comes with the can of resin. Mix thoroughly to avoid any soft, uncured spots in your project. Use a tongue depressor or a stir stick to mix, and make sure to scrape down the sides of the bowl to ensure an even mix. Epoxy resin, in particular, requires thorough mixing.
Be mindful not to mix too much resin at once. Work in small batches to avoid the resin from exotherming, which can cause it to smoke or harden in the mixing container before use. The room temperature will also affect how quickly the resin hardens, so plan your project accordingly.
After mixing, you will have a limited time, typically around ten minutes, before the mixture dries up and becomes unusable. Therefore, work efficiently and carefully to apply the mixture to your project.
Once the resin and hardener are mixed, you can start applying it to the bare dash using a brush. Allow it to dry for about 1-2 hours before proceeding to the next steps of your project.
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Apply the mixture to the dash
To apply the mixture to the dash, start by mixing the fiberglass with the hardener in a bowl. Dip your brush into the mixture and begin applying it over the bare dash. Allow it to dry for 1-2 hours. You can also brush on a layer of resin to the dash, followed by three layers of half-ounce mat.
Next, lay fleece over the dash and cut it to size. Secure the fleece to the dash with glue or a staple gun, being careful to staple on the inside of the dash to avoid damaging the outer area.
Then, apply several coats of the fiberglass/hardener mixture—about 3-5 coats, depending on the desired thickness. Allow the mixture to dry completely.
It is important to test the compatibility of the fiberglass resin with the underlying materials before proceeding. Some plastics can be melted by the resin, so it is crucial to perform a small test on an inconspicuous area first.
Additionally, ensure that you remove all air bubbles that form between the layers of fiberglass mat as you work. A small, 4-inch paint roller can be useful for this purpose.
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Cover with fleece and secure
Covering a plastic dash with fleece and securing it is a crucial step in the process of fiberglassing a dashboard. This method adds less bulk to the dash compared to using multiple layers of matting. It also allows for the creation of a smooth surface that can be painted upon.
To begin, you will need to acquire fleece fabric, which can be found at local auto parts stores or online. The amount of fleece required may vary depending on the size and shape of your dashboard, but a standard guideline is to have at least 1 1/2 yards of fleece fabric on hand.
The next step is to lay the fleece over the dash. This process can be tricky, especially when dealing with compound curves. You may need to stretch the fleece to ensure it covers the entire surface smoothly. It is recommended to cut the fleece around the dash, leaving a little extra material for a secure fit. You can use a staple gun to secure the fleece to the dash, being careful to staple on the inside or backside of the dash to avoid damaging the outer area.
Once the fleece is securely in place, you can move on to the next step of applying the fiberglass and hardener mixture. This mixture will need to be prepared in a separate container, and it is important to work quickly as it will begin to dry within ten minutes. Apply several coats of the mixture over the fleece, ensuring that you cover all areas where the fleece is present. Allow this to dry thoroughly before moving on to the next step of sanding and finishing your fiberglass dashboard.
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Sand and paint
Sanding and painting a fibreglass and plastic dash is a meticulous process that requires patience and attention to detail. Here is a step-by-step guide:
Preparation:
Before you begin sanding, it is crucial to prepare the surface properly. If you are working with a new fibreglass component, it will likely have a thin layer of gelcoat on it. Allow the gelcoat to cure in the sun for 2 to 7 days before sanding. This curing process releases any air pockets in the gelcoat that could cause issues during sanding and painting.
Next, clean the entire surface with a wax and grease remover, especially if it is a new fibreglass component, to eliminate any release agents that may be present.
Sanding:
Start the sanding process with a coarse-grit sandpaper. For the initial sanding pass, use 80 or 100-grit sandpaper. Be careful not to sand all the way through the gelcoat into the fibreglass itself, as this can weaken the component and create holes that will show through the paint later. Sand the gelcoat until it loses its shine; this indicates that you have sanded enough to allow the primer or paint to adhere properly.
If there are any low spots on the surface, fill them with a fibreglass glazing putty. Sand the puttied areas until they are flush with the rest of the surface.
After the initial sanding, apply a primer to the surface and let it set. Avoid using etching primer, as it won't adhere well to fibreglass. Once the primer is set, proceed to sand the entire component again with a finer-grit sandpaper, such as 180 or 220-grit.
Painting:
After the final sanding, you can begin the painting process. If you are painting a plastic dashboard, it is important to first dismantle the different parts of the dashboard to access the plastic components you wish to repaint. Ensure that you know how to reassemble the parts correctly afterward. Clean the plastic surfaces with light washing and soapy water, as professional degreasers or alcohol can leave marks on absorbent plastics. Allow the surface to dry completely before painting.
For soft plastics, use an ultra-fine yellow abrasive sponge for sanding. For hard plastic centre console parts, you can use abrasive sheets with grits between 500 and 800. To check if a piece is already varnished or if it is bare plastic, do a test by lightly sanding it. If you see a white powder, it indicates the presence of varnish, while scratches mean it is a bare plastic surface.
When painting, apply the primer in a thin layer, and cover it with paint and varnish very quickly, ideally within 2 minutes. For the central console, you can choose any colour you prefer. However, keep in mind that it is generally not recommended to paint the dashboard, as a varnish will usually be sufficient to restore a homogeneous and even colour.
Additionally, consider using a solvent-based paint in the "matt base" version, or apply a new matte varnish to restore a homogeneous appearance. You can also explore special effect varnishes, such as a velvet effect (SOFT TOUCH) or a rubber effect (GUM).
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Frequently asked questions
You will need fiberglass resin, a fiberglass mat/blanket, fleece fabric, sandpaper, paintbrushes, latex gloves, a bowl, a Dremmel tool, and a flat hand sander.
First, mix the fiberglass resin with a hardener solution in a bowl. Dip your brush into the mixture and apply it over the bare dash. Let it dry for 1-2 hours. Next, lay fleece over the dash and cut around it, securing it with glue or a staple gun. Apply several coats of the fiberglass/hardener mixture and let it dry. Finally, sand the dash until it is smooth.
Fiberglassing a plastic dash can give it a smooth, custom look. It is also functional as it allows you to mold various components such as pods, monitors, speakers, and gauges.
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