Pursuit Dash Reconstruction

[sftull]

I have decided to take on the project of extending my dash by 2 inches and filling in all of the existing holes. This will allow me to install my new 12" plotter and look like it was installed into a virgin dash. This part of the dash doesn't have any major stress on it, so while I plan on matching the existing thickness, I'm not too worried about getting it perfect.

This afternoon I have purchased the following items:

1.5oz CSM
1708 45/45 DBM Biaxial
Polyester Laminating Resin and hardener
Coridal thickening powder
16oz of PVA
White Gelcoat w/o wax
Gelcoat matching pigment kit
aluminum fin roller

It all should be here next week and I'll get the dash out of the boat this weekend. I will be spraying the gelcoat with a spray gun with hopes of getting a better finish. Pics to come and I will update as I go along. Wish me luck!!

[Carolina]

Tyvek suit

[sftull]

Tyvek suit

Didn't think of that, but good call. I have a good respirator and eye protection.

[ecu1984]

Nothing to it, have done it several times.
Youtube is your friend

[sftull]

This is what I started with, minus the wheel.
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This is with the dash out.
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12" cover sitting where it will go.
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Back side of console
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I will be making a new switch panel and installing a stainless wheel

[Timsmith]

New boat

[USMCsilver]

Looking good thus far. Anxious to see how it performs!

Sent via TapaTalk on S7 Edge.

[sftull]

Looking good thus far. Anxious to see how it performs!

Sent via TapaTalk on S7 Edge.

I just hope I can get it all back together!!

[USMCsilver]

I just hope I can get it all back together!!

I have faith in you. You've done amazing work in the past!

Sent via TapaTalk on S7 Edge.

[sftull]

I got the top cut out and the edges ground down.
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Wood to simulate the dash face.
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Top of dash mocked up. I will glass the inside first and then build it up to match the outside.
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Underside.
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[sftull]

I got the bottom part of the first layer of CSM laid this evening. This is going to be a LONG process.
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[wdhigh]

Good for you! Wish I had the balls to take on such a project. Making exactly what you want has to be a great feeling of accomplishment.

[sftull]

I finished the first layer of CSM. It's pretty obvious that this is my first rodeo but it will look good in the end.
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[USMCsilver]

Schwing!

[sftull]

I got some filled out down and it's covered in PVA at the moment. I need to do some light sanding before I lay anymore glass. I also made some cardboard cutouts or the dash stuff. It's all going to fit!!
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[sftull]

Sorry the pics are turned every which direction. Posting from a phone.

[Maggie Glover]

That is tough crappy work right there. Looks like you are getting close. Did you ever contact pursuit or boat outfitters to see if they had any NOS they would sell you?. MG

[sftull]

Didn't think to contact pursuit. I would imagine those are long gone.

[sftull]

I got one layer of 1708 and one layer of CSM laid down tonight. I had no idea it took so much resin to saturate the glass. I tried my best to get all of the air bubbles out but I'm sure I missed something. I think 2 or 3 more layers of CSM and I'll be close to the thickness of the original dash. I need to add a layer of 1708 to the inside and a layer of CSM.

Should I glass in a thin piece of plywood on the inside or do you think 14 layers of glass will be strong enough?

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[Timsmith]

I got one layer of 1708 and one layer of CSM laid down tonight. I had no idea it took so much resin to saturate the glass. I tried my best to get all of the air bubbles out but I'm sure I missed something. I think 2 or 3 more layers of CSM and I'll be close to the thickness of the original dash. I need to add a layer of 1708 to the inside and a layer of CSM.

Should I glass in a thin piece of plywood on the inside or do you think 14 layers of glass will be strong enough?

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How about a piece of lexan in place of plywood