For reference, I have a 1988 Dak Standard cab and I'm redoing the interior, since it got damaged by sitting with mold and sun.

Firstly, how can you remove the top part of the dasboard? I found some bolts on the side and screws on the top but I want to know if you have to unhook the electronics to remove it before I get in too deep.

Also, for the door panels what is a good plastic filler product? Now that I've sanded off the "plastic rot" I want to give the panels a smooth, shaved kind of look by filling in all the crack and valleys. I have some wood filler putty that might work, but I was wondering if anyone has tried something that might work better on plastic like fiberglass resin or bondo or something.

Thanks for the help
:icon_ pala:

 

I can't remember all that much about removing the dash, but I do remember that the biggest pain in the butt removing the dashboard is disconnecting the wiring harness that runs along the back. It's screwed on in a few places and you can't pull the dash far enough away to easily get to the screws...because the wiring won't stretch far enough. Hard to explain but it just takes some short screwdrivers, finegaling, and patience.

Other than that it's pretty straightforward. Screws along the top, screws down below, all the electrical connectors are super easy, there's not enough to be confusing (trust me, I'm VERY easily confused). Door chimers, speaker connectors, radio power and antenna, HVAC power and vac lines, 12v+/cig lighter, passenger footwell light, gauge cluster connectors and speedo cable, blower motor connector, a ground cable or two, and that's about it. Unbolt the steering column to drop it and easily remove the dash. Two people makes it super easy; these old dashes are brittle and can easily crack if mishandled. You don't need to remove the steering wheel or column, just be careful to support the column (with wood or a jack or whatever) when unbolted so as not to bend it.

No input on the plastic filler, sorry.

 

I'll add that there's a good section on how to take the dash out in the Factory Service Manual. I picked mine up off Ebay (one paper and one PDF version); as I type this the paper starts at $16 and goes up on Ebay.

RwP

 

Those door panels aren't very mod-friendly I'm sorry to say. They are polypropylene, and it's hard to get anything to stick to them adhesive-wise, and even paint-wise. If you really want to try getting a smooth finish on them I'd use an epoxy resin and glass (fiberglass cloth). First though, you need to rough them up enough for the epoxy to get a grip on something. Get them real roughed up and just before you wet them with the resin, pass a butane torch over the panel just until the fibers you've raised start to shrink and the panel gets a slight "wet" look. I followed the torch advice before painting mine and they've kept the finish real well. You have to be prepared to move fast though, so only do small sections. If the panel sits longer than a minute or so after heating, it won't adhere as well. Also, do it outside and/or wear a respirator; plastic fumes are bad for you.

Another, and better, solution is to find replacement panels made from ABS plastic. Much easier to work with. Who sells them? JC Whitney has 'em I believe.