I got a spare dash from the PnP that is just about as cracked as mine with the idea of doing some experiments.

Idea #1 Strip off the vinyl and foam from the sheet metal core and recover with modern materials that are UV resistant. What would be the best way to remove the bonded-on foam and what are sources for new materials?

Idea #2 Split the dashboard horizontally under the trim strips so the top could be easily removed for maintenance or mods. Any thoughts?

I have taken apart the dash before to the point of removing the heater/AC unit. I have relocated relays for easy access, installed an early style cruise control, electric door locks, and moved CIS and lambda boxes to install a right side air vent.

I once had an HP book about custom upholstery for hot rods. It described bonding foam to surfaces and then bonding a vinyl covering over that all using standard upholstery materials and adhesives. Not unlike old style vinyl seat covers maybe. Perhaps I'll take the core to an auto seat cover shop just to get some more ideas about methods and materials.

Yes, filling the cracks with something that would bond with and match the dash would certainly be the best. I'd be a little concerned that the old foam would just crack again outside the depth of the penetration. The bonding compound would have different expansion rates and all that. Still if it were flexible or the foam still had some give in it that would be great.

I'm not really tring to build a dash from scratch just recover the sheet metal core.

Also just get a dash cover, not frabric but the hard cover.A friend of mine got one from JC Whitney and took his time installing it.It was very hard to tell it was a cover!You would have to really LOOK to see it was not original.Something to consider.

I had not thought of those hard covers. That is what I would have if I strip of the foam anyway. I would want to glue it on permanently. I have had the experience of adhesives failing from heat. Perhaps an engine gasket sealer of some type would work. I think covering the smooth hard cover would be easier too.

While flexible adhesives seem like a good idea for a dashboard, most of them have the problem of expanding and contracting with the temperature. This (and UV damage) is the reason our dashboards crack in the first place.

I'm inclined to say that if you're installing a plastic dash cover, epoxy would be a good choice. It can handle a fair bit of heat and bonds well to most substrates. Scuff the vinyl with 180-220 grit sand paper and squeeze out a couple tubes of epoxy onto the dash.

Just a thought. I'm very interested in what you're doing. I just spent the weekend before last swapping in a junkyard dash with only one small crack. I have an extra dash laying in the yard, wondering if it's worth it to try (again) to repair the cracks for the future.

The only thing you have to lose is time and a little money.I don't know what type of foam you would use but I don't think it has to be special.After stripping the dash apply spray adhesive and then carefully lay your foam as evenly as possible and allowing enough overhang for trimming.The hardest part will be the dash material.But I think a good quality vinyl and a heat gun are going to be your best friend.I have not recovered a dash but have seen some shows on TV [pimp my ride and West coast Customs]where these guys do everything.They always use a heat gun. A lot of stretching and pulling and spray glue and smoothing out with the hands,you get the picture.Sounds like a fun project. I did recover a dash a while ago.It was a 69 Chevy Impala.I covered the dash in faux black fur!I also did all the trim around the windows and doors,rear package shelf.Just went nuts.Had a cool looking pimp mobile for while.Also had 4 other people come to me to do their cars! Fun summer.

The heat gun is a must. I have even taken 20 year-old dash pads and made the vinyl pliant again with a heat gun.

Here's where I think you'll have trouble: I once used a high-quality spray adhesive to bond a piece of vinyl to the cardboard rear deck (or package tray, whatever you call it) in my 240 and after 6 months, the heat from the sun hitting that black vinyl had melted the glue enough that the vinyl peeled and flapped in the breeze.

I used a very heavy-weight, fabric backed vinyl from the fabric store (about $15/yd) and Permatex headliner spray adhesive, and even without the complex corners and stretching, the glue failed in the heat. I cannot see a re-covered dash faring any better. Prove me wrong; I'd love to know that it is possible.

Have you considered a hard dash? I have thought about an all-wood dash built on the metal frame, or a painted fiberglass dash. BTW, the fiberglass thing has been done. A Turbobricks member encased the dash in fiberglass (possibly after stripping off the vinyl), then sanded and painted the whole thing.

Good luck, and give us updates!

Recover the sheet metal core and build and form the foam around it?! I haven't read of anybody doing that yet. Sounds like special machinery and talent required. Try other options first.
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1980 245 Canadian B21A with SU carb but electronic ignition and M46 trans in Brampton, Ont.

Trev, I'm pretty sure someone posted about a California outfit specializing in rebuilding dashboards, and the recollection I took from it was that it was a molding process, where the market was collector cars. I agree, anything I could think up would make Volvo's suggested list part price look way favorable, as did theirs. I guess that post may be also in 81's memory too.

In the way of being even the tiniest bit helpful, I have two 83's both sporting the dash covers (blue) that have held up very well over the 6-7 years of my stewardship. The material is thick enough to hide the location of the cracks in the dash beneath them. But, as with most of our projects, the care and skill with which they were attached (by the PO's in my case) probably played a great part in the success.
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Art Benstein near Baltimore

If you lend someone $20 and never see that person again, it was probably worth it.

I think they are called Just Dashes.

I wouldn't even know where to begin building a dash from scratch. I don't know what kind of foam would be appropriate, nor how I'd form the vinyl to it. However, I have fixed cracks in the dash a few times.

First time I used paintable caulk; bad idea. The caulk bubbled up when it got hot and cracked the paint I'd put over top.

I tried super glue to fix a very small split, flooding the crack, letting it dry, then repeating. It seems to have worked okay.

My last attempt was with 5 minute epoxy. It filled the crack well, doesn't change in heat or cold, and I suspect it boned with the vinyl and foam. I'm expecting the epoxy to last a long time. If you dyed your epoxy to match the dash, then found a way to impart the grain of the dash before it hardened completely (a greased piece of textured plastic?), I think you could repair the cracks with good results.

I haven't looked at a dash carefully, but have got the impression that if you can replace the foam successfully then you can build a dash from scratch.

I'd try filling in the cracks and maybe painting it (textured paint?) or gluing a vinyl covering over it.
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1980 245 Canadian B21A with SU carb but electronic ignition and M46 trans in Brampton, Ont.