How's this for a start patch-panel?

 

That looks very good! Well done.

 

It's a start, that was only 12 ga aluminum.
be a lot less wavy with 0.034 steel. Not sure if I should:
Cut our dash section, then install it EPDM "H" channel, or
end a flange into it and install EPDM "U" channel around the dash.

 

That looks very nice, but two things. First, how would you incorporate it into the dash, and two, aluminum has a very different rate of expansion and contraction compared to the material the dash is made of. I would think that even if a seamless repair were made, the differing rates of expansion would tear a line around the panel.

 

Not gonna be made of aluminium, will be .034 steel, paint to match, planning to
cut speaker area out, use an EPDM "H" channel that will hold the panel and hold the original dash. (just like how your rear window is held in by the gasket) "Wiggle room" will be in the "H" channel.
there is no way to make any repair "seamless" being the nature of brittle vinyl.
Only seamless is a complete recover, and we've seen what happens there.

 

I was searching the forms, and found a solution to fixing the dash and installing aftermarket gauges
[/QUOTE]

 

Not sure I like something "staring back at me"
I think bondo will crack going down a few roads around here!

 

There is a fiberglass that will flex and not crack..

hmm...

 

I don't like it at all. Looks like it would be in the way when driving. And it shouts ADDED ON!

 

Fiberglass filler. I've hit that stuff with a sledgehammer before and it didn't break.

 

Almost done with my patch, maybe by this weekend.

 

There's the proto.
Held in with "C" channel and machine screws from under.

 

Wow! That looks good. Can you take a close-up of the joint between the vinyl and the metal? It isn't clear to me if the metal is on top, on the bottom, or a really nice joint between the two.

 

This one over laps all cut edges about 3/8"
This one has a bigger border that the ones I'll make in the future, because you will only cut around the existing speaker holes.

I made the hole in the dash bigger than the actual speaker hole area to try and fit a rubber "U" channel between the patch and the vinyl. So this patch is bigger. didn't work well for "ease of installation.

The border on this one is 5/8".
all others will have a border of @ 1/4"
Clips are not done yet, but the panel will sit snug on top of the vinyl.
(I figured YOU would ask about the "joint")

I suggest to "hot glue" or any other way to bond the edge of the vinyl after cutting. this will help form the vinyl from cracking at the new cut.

 

LOL! Ok, my reputation is well established.

Anyway, that should work. Thanks for the explanation.