Aftermarket FJ40 Dash Pad

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Working Late Nights

:bang:Just wanted to give you guys and update as I'm getting regular e-mails and PM to finish the lower dash pads.

You guys and girls can thank Mr. Sea Knight for the projects delay of about three hours. I started reading his thread "Saving the Old Rusbucket" and next thing I know three hours had passed by!::bang: (I'm a slow reader but darn that is a good read!!!)

I need to get a job at McDonalds flipping burgers, because when it's all said and done I would no doubt make better money than jacking around late at night trying to make this project work. But what do they say?................It's an act of love!!!! LOVE SUCKS But we must push on:grinpimp:

Got the left lower dash pad attachement points map out! Woo Woo!!

Drilled out these attachment mounts. Inserted the receivers for the mounting attachment.

Pretty much the left lower dash pad tooling is ready to mold product.

Spend two hours sanding and machining on right long lower dash pad. Mapped all of the attachment points (Basically the screw attachments that mount underneath the dash but still need to map out main attachment points.) Sanded Sanded and then Sanded tooling. Next is mapping out the solid attachment points to the main dash. I conquet this next week.
 
Progress Or Lack of it

I lie I lie...........Like a rug.

I thought I would post an update on the progress or lack of it.

The lower right hand dash pad has more waves than the Pacific Ocean. I have about 10 hrs total sanding in this tool alone. This is the part of tooling/plastic processing that I hate with a passion. On OEM projects we figure a machinist or tool maker doing this. They are faster and have a lot of tricks to their trade.
However, this project is different due to the low volume of products being sold, therefore I am stuck down here with 60 grit sand paper in hand! :censor::censor::censor:

Getting close though. Lower Right Hand pad is taking shape. I have most of the waves out now working on the corners and turns/transitions. Wife is mad because I stayed down there til 9 pm sanding on it. Gotta be honest though, at least one hour was reading "Saving the Old Rustbucket" I'm at the part where Sea Knight went back and camped out at the Hotel after meeting Gayla!! That read is more addictive than crack cocaine. Once you start it's hard to stop.

I am trying to put in as many hours on this in the next couple of days to advance the project, as Thursday night we're headed down to Disney, OK for the "Big Meat Run".

Mabe I might see some of you guys there! If so, stop by and we can have a :beer::beer:
 
Are your FJ40 dash pads in stock and still have the logo on them? Are you planning to do another run without the logo? With a restoration it's tough sell with it big and bold in front of the buyer.

Thanks for all your hard work.

JC
 
Yes they are in stock,

Diskord recently sent me a pretty good picture of one he just installed. The Logo is not really that bad and I've yet to have someone purchase one come back and tell me that they were not completely satisfied. I'll see if I can't find it and post it.
 
Must..............................have............................lower.....................dash.................................................Pads
kirk_hunched.webp
 
Lower dash pad prototypes

GOOD FRIDAY:bounce::bounce2:

I've been playing on the lower dash pads today.

Got all the tools mapped out for receivers of inserts.
Venting accomplished on two tools.
Injection Ports/Gating done on two tools.

The Lower dash pads were actually harder than the upper dash pad as you have two planes of attachment points. Had to break out the old slide rule abacus on this project:doh::doh:

Got the first Prototypes out of the Left Pad and the Right Pad. Center pad is the easiest one so I will jack with it later.

See pictures.

All that is left to do on these tools is play with the chemistry to get desired density. Right now they are pretty dense and as a result very difficult to demold. Need a jackhammer to get it out of the tool!:bang:
Overhead Right.webp
Left view Right Pad.webp
Right view Right Pad.webp
 
Left Lower Dash Pad

I also need to texture the tooling to match the upper dash pad. In the left dash pad picture below you can see aluminum dust that came out of the tool imbedded in the urethane.

I am very happy with the mounting selection. We went with 10-28 threaded inserts rather than the push pin. I left approximately 0.400" of thread exiting part in order to mount a nut on the backide of the dash.

I did this due to past experiences of tearing a dash pad when removing with the push pin / clip Toyota OEM fastening method (They Rust). Mounting bolts all matched up with existing holes on dash as well as the lower screw holes mounts underneath.

SCOTCH TONIGHT
:cheers::cheers:
Left Pad.webp
 
Very nice outcome.
 
Slight delay in the progress of the lower dash pads.

Went back and took a closer look last night and I believe I am 0.12" off (Basically 1/8") on mounting of the dash than what I believe it should be.:bang::bang::bang:

I will fix it this next week. We're getting close boys and girls!!!:cheers:

Prior to any changes I will scour the internet for original lower dash pictures.
 
I think you're right. They look absolutely amazing! but they seem to be sticking out past the sides of the dash by a little bit.

Can't wait to grab a set.

Edit: went out to mu truck... The stock pads stick out a bit but it looks like the cut at the end isnt as sharp of an angle as yours. Could be three angle of the pictures though

fjgoober said:
Slight delay in the progress of the lower dash pads.

Went back and took a closer look last night and I believe I am 0.12" off (Basically 1/8") on mounting of the dash than what I believe it should be.:bang::bang::bang:

I will fix it this next week. We're getting close boys and girls!!!:cheers:

Prior to any changes I will scour the internet for original lower dash pictures.
Click to expand...
 
Last edited:
Would like to order your roll bar pads.
I need a set of the pad that go on the joint.
What is the price for the set?
How can I order them?
Thanks,
 
fjgoober said:
Slight delay in the progress of the lower dash pads.

Went back and took a closer look last night and I believe I am 0.12" off (Basically 1/8") on mounting of the dash than what I believe it should be.:bang::bang::bang:

I will fix it this next week. We're getting close boys and girls!!!:cheers:

Prior to any changes I will scour the internet for original lower dash pictures.
Click to expand...

Here are some from a new thread that address the left piece:

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igniter3 said:
Would like to order your roll bar pads.
I need a set of the pad that go on the joint.
What is the price for the set?
How can I order them?
Thanks,
Click to expand...

You can click on the banner in my signature line or go to www.fj40dash.com The joint we do not manufacture (We have had very little demand for it to justify building a tool). If we do end up manufacturing that piece it will be quite some time. The other 4 pieces in the roll bar sell as a set with free shipping.
 
I didn't explain myself in an earlier post regarding being off. The bolts are 10-24 which allow for some adjustment of fit left or right due to the existing square hole in the metal dash.

Where I am off is in the vertical plane. You really can't see it in the pictures unless you blow them way up. On the Right and Center pads there is a crease in the metal dash. When I mapped the tool for some reason or another (Still haven't figured where I got off) I put the inserts approximately 0.125" higher in the pad so the pad now sits 0.125" lower on the metal dash.

Fixing the tool to accomodate this change will not be that difficult just finding the time to get to it is the dilemma.

I will get to it though.
 
fjgoober said:
You can click on the banner in my signature line or go to www.fj40dash.com The joint we do not manufacture (We have had very little demand for it to justify building a tool). If we do end up manufacturing that piece it will be quite some time. The other 4 pieces in the roll bar sell as a set with free shipping.
Click to expand...

Thanks for the info. at this time I really need the pad for the joint, my joint pads start to fade out due to the previous owner is not taking care of them.
I will definitely buy the roll bar pads from you in the near future.
Thanks,
 
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