Jet Jockey/A4 Pilot

Turned out excellent, much better than my original material finish that was glued on. Very happy with the end product.

<b>First a look at my initial mod to my dash (back in January)...</b>


The dash before its initial transformation.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Weightreduction-Jan052008001-1.jpg">


The underneath portion after lots of fat trimming.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Weightreduction-Jan052008007-1.jpg">


The open end piece of what is left from the defrost duct.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Weightreduction-Jan052008009-1.jpg">


After some more weight trimming.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Weightreduction-Jan052008012-1.jpg">


And now the new/old finish after a fake suede like material was glued on. The problem with this set up is it wasn't going to look good that long. Indeed we already had to fix it once or twice.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-ModifiedHVACInstall-Jan27-20-8.jpg">


<b>Now for the newer finish and some extras...</b>


First we plastic welded some plastic to close off the endings of the defrost duct.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-AIMMXLPista-May2008002.jpg">


Then we used some expending foam to block off the holes that made up the original vent outlets. These were later trimmed down. You can also see that the upper surface was taped over with aluminium tape to hide the round cut outs.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Dashremake-May2008001.jpg">


Close up of the centre vents.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Dashremake-May2008002.jpg">


To further secure the round cut outs a thin layer of hot glue was added to bond onto the aluminium tape.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-AIMMXLPista-May2008007.jpg">


Then two small aluminium right angles were riveted in place.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-AIMMXLPista-May2008004.jpg">


Close up of the riveted aluminium piece.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-AIMMXLPista-May2008003.jpg">


Finally the final product of the finished dash. Because I don't have the pictures showing the actual process on how the material was applied, I can tell you a special black glue is first applied to the dash and then it is taken into a small paint booth where the material is sort of spray painted on.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OEMUpperdashremake-May2008001.jpg">


Close up of the finish product. It's almost like a very short crew cut haircut, LOL.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OEMUpperdashremake-May2008003.jpg">

sparkhill

Looks a lot more finished now