HOW TO BUILD A THREE-GAUGE PANEL IN THE PASSENGER AIRBAG CAVITY ON A 1994-1997 MIATA
(Above) Using Photoshop, I flopped into LHD orientation
NoPro's RHD-oriented NB airbag gauge pod (note the reversed text on gauge faces). FYI, in Japan, the NA never had a dash with a passenger airbag. All Japan-spec NAs had the same style dash as USA-spec 90-93 NAs.
Built particle board base to fit in cavity and screw into position so location was repeatable. Made three 2" I.D. gauge alignment tubes out of two diameters of PVC plumbing pipe. Found makeup compacts at .99 Store with 2" diameter mirrors. Epoxied a mirror at back end of each tube, perpendicular to tube.
Squished equal-sized blobs of Plastalina clay under each tube assembly. Positioned tubes so mirror at back of each tube was aimed at driver's POV (see camera lense in mirrors). Removed wood base/tube/clay from dash. While still attached with clay to the board, applied fiberglass to tubes to attach them relative to each other. Removed linked tubes from clay and applied fiberglass to undersides of tubes as well. Replaced 3-tube assembly on clay on board, replaced assembly in dash and adjusted clay as necessary to re-align mirrors.
Applied 3M blue masking tape to dash around hole. Put 3M mold release wax over tape. Injected
Dow "Great Stuff" aerosol foam behind and around tubes to fill cavity. As foam expanded, it spilled over onto the dash. The foam is very sticky until it dries.
Sculpted the foam down to size, allowing for a 1/4"-3/8" thick layer of
Bondo.
Covered foam with Bondo. Wax-covered paper cups were inserted to retain shape of holes.
Bondo
SurFormed and sanded down.
Still to do:
Once the gauge holes are shaped, the entire assembly will be removed from the dash. A urethane mold will be made from the Bondo surface. Fiberglass will be applied to the mold, making a thin, rigid part. Hinges will be epoxied to the underside so the panel can be tipped up for access to the gauge wiring. The panel will be primed and painted to match the rest of the interior. Gauges will be mounted and held in by friction.
More pictures to come as the project is completed. Thanks for looking!
If interested in getting one of these made, email me at Bill@MiataRoadster.com.
