[This message has been edited by Sourmug (edited 10-14-2006).]

As of today the interior looks like this:



Everything has been taken back out of the interior. I fell like I'm back at square one. But there is some small glimmer of reason in my madness. I am in the process of doing a few tweaks and getting the inside ready for the sound deadener that I bought in the latest group buy.

If you recall, I made some fiberglass infill pieces to cover the gaps in the dash top where the Stealth A pillar sits. I have never been happy with the one that I made so I decided to redo them by first making a pair of "blanks" off of the stock Fiero dash. I first covered the dash with masking tape and then applied 2 layers of mat:


Here is the piece once it was pulled off of the dash and the old filler pieces were used to mark the required outlines:

[This message has been edited by Sourmug (edited 05-29-2007).]

The reason for using these stock dash as a mold is that it gives me the two corner shapes to match the stock dash and also gives me the needed line along the windshield. The use of only two layers allows these pieces to be flexible for insertion once the dash is in it's final position.
Once the pieces were rough cut I did some trial fitting. The driver side piece needs some modifications that can only be done with the Stealth dash out but the right side piece is a near perfect fit:


Once the stealth dash was removed I did some additional fitting on the drive side piece. I needed to add a curve down on the"flap" that covers the side opening. To do this I cut some kerfs in the side of the piece which allowed it to be bent and then glassed it to hold the shape. Once set the piece was attached to the dash in it's proper position and additional glass added to match the Stealth dash contours:

The dash was covered with packing tape prior to applying the mat and resin. They now need to be cleaned up, sanded and filled. Here are some comparison pictures:



The other thing that I have been working on is the little triangular gaps that the sides of the Stealth dash have vs. the edge of the door trim:

The one on the passenger side is slightly bigger. Also the driver side dash end sticks out a bit at the bottom and needs to be trimmed back:

[This message has been edited by Sourmug (edited 05-29-2007).]

To trim the end cap I first marked out a wedge of material that is going to be removed:

And then cut it out with a very fine cutting wheel on my angle grinder:

The lower driver-side dash half is actually metal so once the piece was removed it was bent into shape:

And reinstalled to check the fit:

The triangular gap on both sides is going to be covered with a fiberglass end cap. This cap will also cover the damage caused by cutting the wedge out of the dash bottom. But first a mould of the door trim was made to allow the future end caps to tie directly into the molding:

[This message has been edited by Sourmug (edited 05-29-2007).]

The position of the triangular gaps were marked on the molding along with the dash ends. The white sheet styrene was placed on to approximate the dash end position. Then two layers of glass were applied.


Here are the pieces before and after initial trimming:


They will be used to fill the gaps and be incorporated into the end caps once the dash is back in place.

Nolan

[This message has been edited by Sourmug (edited 05-29-2007).]

Well not too much progress as of late, work's killer right now.

I have managed to rip out the after-market alarm system that a previous owner installed:

Working on making some switch panels for the lower dash:

Modified the center bracket for the dash due to some interference when I make the trim pieces for the Stealth console. I had to trim it down a bit on one side:


And I have acquired a few things:
The Tweeter infill pieces for the dash:


The sound deadener from the group buy in this Thread has arrived. I purchased the 100 sq. ft. option and it comes in two rolls:

And with instructions, roller, degreaser, utility knife and some ties. Not to mention the ubiquitous sticker that's got to be good for at least 0.221 horsepower!


And I also picked up 3 - 1" thick sheets of rigid fiberglass insulation from a contractor at work:

I will be using this to sculpt some of the features on the door panels and center console. Hope it works...

Anyways that's it to date.

Nolan

[This message has been edited by Sourmug (edited 05-29-2007).]