DIY Network

'66 El Camino: Custom Dash It's paradise by the dasboard lights as Andrew and Christie create a custom gauge cluster that's certain to inspire dash envy. From "Resto Rides" episode DRRD-104

	Andrew Totolos puts the finishing touches on the El Camino's custom dash.

While the car is away at the paint shop, Andrew and Christie make over the dash with a new look and a new set of gauges to monitor the fuel-injected LT-1 engine.

The steps in this phase of the restoration, as seen in episode 104 of Resto Rides, are summarized below.

Materials and tools:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), the essential tools required for this phase of the project are listed below.

pick tool
cardboard
marker
plywood
compass
hole saw
drill
utility knife
spray adhesive
foam board
microsuede
staple gun with staples
drawer handles

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Note: This is a summary of steps included in the restoration procedures shown in this episode of Resto Rides. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Custom Dash

• The first step in building the custom dash is to remove all the old parts. Andrew and Christie start with the air-conditioning vents. They decide to save these because they're in good condition.

• Then Andrew pulls out the old radio, while Christie removes the switchgear so they can replace the upper trim panel behind them later.

• A pick tool with a pointed tip is ideal for removing the old bezels like the one on the windshield wiper switch.

• Next, Andrew pulls out the cigarette lighter and the center air-conditioning vents while Christie removes the old broken gauge cluster.
  After all the original parts are stripped off the dash, it's time to start building the custom dash.

• First, they trace out a template on the inside where all the gauges were onto a piece of cardboard. They can't reach to trace the entire dash, so they trace one side and then flip over the cardboard to get the mirror image. Then they trace it over the other side to get the full length of the dash.

• After the cardboard is cut out, Andrew and Christie transfer the template onto a piece of thin plywood that will provide the structure for the new dash.
  

  	Figure A
  	Figure B
  	Figure C
  	Figure D
  	Figure E
  	Figure F

• Next, Andrew cuts out the gauge panel using a jigsaw. The cut lines should be pretty straight, but since the board is going to be covered with upholstery it will be okay if they board is a little smaller than the opening.

• Next it's time to lay out the gauges. Christie marks the edge of the gauge area and the top of the steering column to center them up. Then they use the radio's mounting sleeve to mark its location.

• They mark a horizontal centerline on the panel so all the gauges will be straight. Then they use a compass to draw out all of the gauges equally spaced from the steering column out.

• Andrew uses a hole saw to drill out the smaller gauge holes, and then switches to a larger bit for the speedometer and tachometer. He finishes up with a jigsaw to cut the opening for the radio (figure A).

• He drills a few holes for the LED turn signal and check engine lights. Andrew and Christie test-fit one of the bulbs to make sure the holes are the correct size.

• After they cleanup their work area, Andrew and Christie lay the panel on top of some high-density foam and trace the outline and all the mounting holes. They use utility knives to cut out the piece (figure B). The cutouts for the gauges and the radio are beveled at a 45-degree angle so that they pieces will sit deeply in the padding once they're inserted.

• They use a spray adhesive to attach the foam to the plywood panel.
  
  
• Then they lay out some elastic microsuede that will conform to the contours of the dash. The microsuede is cut to a manageable size and smoothed out, and then they use more adhesive to attach the microsuede.

• After the material is wrapped around the back of the piece, they use a staple gun to attach it tightly (figure C).

• The microsuede is stretchy, so it's easy to cut the piece of fabric from the cutouts for the gauges (figure D). Once the gauges have been inserted into the new dash (figure E), they'll hold the material in place.

• Now it's time to insert the gauges and the LED indicator lights and tighten them down from the back (figure F). They also pop the radio mounting sleeve into place and bend up the ears to hold it in tightly.

• For a final aesthetic touch, Andrew and Christie screw in drawer handles to the sides of the panel so it can be easily removed if need be.

• The custom dash is almost complete as Andrew and Christie attach the new custom panel to the original dash. They use angle brackets to attach the panel to the dash. First, they mount the brackets to the board with Allen head screws. Then they hold the panel in place, drill through the original dash into the brackets, and screw the new panel in with sheet metal screws.

• When the panel is attached, they install a fresh trim panel for the switches on top of the dash.

• Finally, they reinstall the air-conditioning vents to their original locations.

RESOURCES :

Special resources for DIY's Resto Rides 100 series: 1966 El Camino

Original Parts Group, Inc.
www.opgi.com

Husky Tools
www.huskytools.com

Rick's Hot Rod Shop
www.rickshotrodshop.com

Vintage Air, Inc.
www.vintageair.com

Fuel Injection Specialties
www.fuelinjection.com

Lokar
www.lokar.com

K & N Engineering
www.knfilters.com

Nordskog Performance Products
www.nordskogperformance.net