Dashboard
Turns out the original dash frame was bent and bolt holes did not line up. I was concerned for a bit but test fit of the replacement dash frame showed all the bolt holes line up.
With this information I moved the original wiring harness to the new frame and reassembled the whole thing. To make sure I got everything connected in the right places, I removed the harness from the dash frame one or two connections at a time and installed the original right after.
After assembly and other prep I installed the dash. Install was pretty straightforward, and this job is so much easier with no windshield and no front seats. Lots of bolts and small screws to install, and wires to connect. I had labeled most of the connections which helped.
Other
Kurt did the final welding for the lower A pillar sheet metal panel. Cleaned up the welds and got some paint on them
Obtained and installed the brake booster
Prime and paint the scratched areas in the windshield frame – before dash install to avoid spills/cleanup. Did brush touch on these since none of this will be visible
Got busy with expanding foam in the driver side frame rail and lower windshield brace – replacing what was removed during repairs. It took about a can’s worth
Remove deployed side curtain airbags and install replacements. This took longer than expected as I had to remove visors, hand grips and clothes hangers to move the headliner to access the bolts holding the airbags in. Also found a small rip in the headline presumably from the airbag deployment.
- Thank you Dave Bales for the air ratchet - perfect for this task
Install the front carpets – these loop in over the lower dash support brackets. Also put in the ducting that goes under the carpet to the back for the car
After the dash was installed, the steering column, glove box and gauge cluster were installed. There is a metal ring that holds the seal at the firewall, and of course it was bent. Each time I find another bent item I wonder if this is the last surprise from the crash. The brake booster had that title for about a week.
- not sure why I was surprised this was bent.
Definitely into a new phase for this project - still a long way to go but expecting a lot more assembling and less fabricating from here on in. After looking at this shell for so long it's really nice to see it starting to come back together.
Also - now over 525 hrs I'm hoping less than 200 to go