65/0038R Restoration process

[BDA]

From putting in the dash to starting her up and no updates... Jason, we have to talk!

What does she look like now? What have you done? Inquiring minds and all...

[JasonH]

Well... I got quite a bit done.  I am trying to attach photos but having difficulties.  I logged out and back in  I will make an attempt...

[JasonH]

I get a message that says that lotuseuropa.org cannot "handle the request"  I have resized the image and it is @ .99 MB.  Which should make it?

[BDA]

 Have you seen this http://www.lotuseuropa.org/LotusForum/index.php?topic=1379.0?

[JasonH]

Thanks. that was my old method.  I tried a new one (new to me anyway)  and maybe that is why it is not working.

[JasonH]

Dash repaired and prepped for Veneer.  Ok. that was the problem. Darn.  because the "new" way was much quicker.

[JasonH]

The veneering of the dash was a bit more problematic that I anticipated.  The dash was pretty severely de-laminated, and I re-glued it with epoxy.  However, the "ultra cat"veneer glue  didn't like the non porous surface in spots.  No hint of adhesion!  I had to go back and squeeze epoxy into the voids and clamp.  Attached is another shot of the dash under vacuum to the veneer.

[JasonH]

In hindsight I should have just used epoxy to glue the veneer to the board.  I also should have attempted to flatten/relax the veneer.  I got impatient and just wanted to get it glued on so I wrestled with the veneer trying to roll back up to it's shipped position.  (Interesting message on the packaging of the veneer. Felt like I was unpacking a bomb.)

[JasonH]

I definitely made a rookie mistake by trimming the veneer without first applying a coat of clear or epoxy first.  The veneer was so thin that it easily split without having a binder absorbed into the wood fibers.  This can be seen with the chunks around the binnacle aperture, and around the windshield wiper switch opening. I should have also taken more time to fill the voids with a better matching colour, but didn't 

[JasonH]

After massaging out my mistakes.  I proceeded to lay on 7 coats of Glasurit clear.   I spent the better part of a week painting, sanding, painting, sanding.
I laid down 5 build up coats, a lable application, and then another 2 on top. I was super paranoid on my last sanding/leveling.  I was worried about sanding out my labels!  However, I took my time and didn't make any mistakes on this task.  I feel if I had applied the epoxy to the dry veneer I would not have spent so much time with the clearcoat.  Finishing off I did a three stage buff, and the results were acceptable.
I looked around for photos of the finished product but can't find them.  Just this one (before the last 2 coats) getting measurements for fitment.

[JasonH]

Done posting for the day. 

Next: Fitment of the dash pad

[BDA]

In spite of the "rookie" mistakes, it came out really good! If you haven't installed it yet (and at the risk of  ), I would advise you to finish or at least seal all the edges of the plywood so moisture can't get in. BTW, I'm not disparaging your work by calling your mistakes "rookie." I would never trust myself to try a job like that! If I'm a danger with a wrench in my hand, I'm a disaster with wood working!

Also, the method of resizing pictures I pointed you to is not the way I do it. If you want to experiment, what I do is display the picture on the screen. The last couple of versions of Windows came with a utility called "Snipping Tool" which allows you to save a picture of all or a portion of your screen to a file. I use that utility to save either a part or all of the picture to a new file and I attach that to my posts. In the end whatever works!

Keep up the good work!

[Certified Lotus]

Take pride that you did it all yourself......including some of the small mistakes. I took the easy way out and bought a new one. You get more points from me for doing it 

[dakazman]

  Nice job Jason, nice finish!  are you going to add any lettering to the panel?  You brought back memories of my rebuild not to long ago .
 Starting here, http://www.lotuseuropa.org/LotusForum/index.php?topic=2058.300.
 I still have to put it back together With all new gaskets and seals.
Dakazman

[surfguitar58]

Dash looks great! As an amateur woodworker with perfectionist tendencies myself, I can say with confidence only YOU will see the microscopic flaws in the veneer. Everyone else will see a job well done.
Tom