Why My Dash Creaked

[eye of ra]

This was not a job I had originally planned on doing as part of the restoration however on removing the dash to do something else I discovered what was making all the creaking noises.

Every arrow is a completely snapped piece of plastic, a crack or a disintegrated screw hole.



The * are where the whole area had disintegrated and the only thing holding the dash to the A pillar was the vinyl.

The two other parts of the dash/instrument surrounds are only damaged at the screw holes, other than the usual crack on the top left.

Hope the repairs hold when it goes back together.

[dcwalker]

Ah, good old Volvo 480 quality materials and build

I am fortunate in that my dash does very little in the way of creaking and rattling, so I daren't look into the state of all those screw holes on mine! Best let sleeping dogs lie...

Good luck with the repairs and reinforcements!

David

[jifflemon]

Its something I'm sure we're all familiar with!

I'm still not happy with mine, will be pulling apart again soon.

[arthuy]

What are you using for the repair?

I have had things like this on other cars and wonder if it would help to fitting strips of aluminium over groups of screw holes to give more strength/rigidity to the dash panel either bonded to the plastic or just held by the screws.

[kissato]

This is topic that is dear to us all. Because if you don't have a crack dash you will have eventually. The plastic used is extremely week and get worse and worse with age getting more dry...

Let me tell you about my experience and how I thinking on solving it.

Last summer I had the bright idea of removing the grey vinyl and flock the dash, this was stupid as hell because the vinyl holds the dash together although in my defense prior to this i had the dash repair and reinforced by a plastic specialist, and in thought that would be enough. It wasn't... and it started to crack in new places and without the vinyl now it's visible.

The solution I imagine it works and eventually I will try is with the dash out like yours right now, to reinforce all the back part of it with epoxy and lots of fiberglass so it glues to the old plastic making it stronger. A good layer of up to 5 mm wont affect the assembly of the dash.

Also one idea would be to make a mold of the dash and had ti made in carbon fiber.

Anyway if you do this or find another solution please take pictures or even do a DIY. This will be very useful for the community.

[malkontent]

In many cases it is because someone was there , I did 3 dashes and no all fasteners were cracked . It was long ago but if I remember some screws are from outside the car.
The quality of plastics and assembly is another story . This is not a " good old Volvo " . As I was a spare parts importer , had many parts in my hand and I can tell why Volvo was and is in trouble . Stupid cuting cost politics and poor quality . Some mouldings were manufactured in USA and Swiss ! After sell to Ford , the stupid gringos ruined old parts stocs and this was the end .

[dragonflyjewels]

My es is currently on sorn and without its perfect (for now!) dashboard. I took it to see if a mould can be made in order to produce sturdier replacements. Apparently it's a very complicated shape - just awaiting final verdict on whether it can be done. Fingers crossed - despite having replaced the dashboards in all 4 of our cars over the years, this is now the only one without any cracks. sigh..............

[eye of ra]

The solution I imagine it works and eventually I will try is with the dash out like yours right now, to reinforce all the back part of it with epoxy and lots of fiberglass so it glues to the old plastic making it stronger. A good layer of up to 5 mm wont affect the assembly of the dash.

Anyway if you do this or find another solution please take pictures or even do a DIY. This will be very useful for the community.

When I put it back in I will take some pictures and do a how to, assuming it all stays together.

The repair is as you have said mostly fibreglass and some epoxy resin, you do need to sand/grind the surface so it’s not smooth or it won’t stick, ask me how I know.

There is not a lot holding it in to the car as malkontent says 4 bolts from outside the car, also 4 into the A pillar that’s about it. The rest are holding things to the dash like the heater and centre console.

And then the big issue, the wiring (which I do have pictures of so I can hopefully put it all back as it was) and is why I would suggest removal and reinstall is done by 3 people. One each side supporting the dash by the A pillar and one to disconnect/reconnect the countless connections. The wiring is entangled around the dash and heating and is heavy, not can’t lift it heavy but it is break plastic dash heavy, so you are likely to damage the dash further on removal and/or ruin the repair on refitting.

There was info out there that I used and wish to say thanks, this being one of them

http://www.volvo-480-europe.org/forum/v ... 24&t=34282

But I did do it before Photobucket went mad.

[dragonflyjewels]

I downloaded glasgow jim's how to on removing the centre consol, complete with photos, plus jifflemon's additional notes and put them into a Word document I could print off for hubby to change my carpet. If anyone wants a copy, just pm me your email add and I'll send it to you.

[kissato]

eye of ra, I totally agree that a good surface preparation needs to be done.

Looking forward to see the process and the result.

[malkontent]

Is that you need ?