New Kick Panel for 1st Gens

ARE THESE SOMETHING THAT ARE BEING SOLD AND IF SO WHEN ? THANKS RICH

Thanks for posting those Instagram photos. I had heard about them but couldn't find them. Any idea who's making those? I see a couple details missing.

I do have some ideas for the floor mat! But this kick panel is what's been keeping me from assembling my dash.

Yes, I will be selling these but I want them to be right. I can cut these out of the panelboard or this cool corrugated plastic.

I told my laser guy that these are supposed to have insulation on the back. He said we could try mounting some to the back of the board first and then do the laser cutting. Looks like that's what that guy on Instagram did. And I'm sure the factory cut both at the same time too. First we need to see if the laser sets jute on fire!

The shop manual says:

Parts to be removed and installed for replacement of the dash mat are as follows:

1. Windshield wiper hoses from wiper motor.
   
2. Windshield washer bag bracket.
   
3. Electrical harness from the quick disconnect under the dash.
   
4. Junction block.
   
5. Speedo-cable at instrument cluster.
   
6. Loosen the metal electrical harness shield on the toe pan.
   
7. Headlamps.
   
8. Heater distributor and outlet ducts. Do not remove the heater.
   

3 is the connector above and to the left of the fusebox, that goes to the rear lights.

4 must be the fusebox.

5 - I did remove my speedo-cable but I'm thinking we don't have to. I'm pretty sure it runs behind this kick panel.

6 is that little black plate in the floor where the wire harness goes through the floor to the doghouse.

7 - I did not have to remove my headlight buckets, but it would be a bit easier if they were out.  

8 - It's true that the panel will fit over the heater but what about the heater core pipes? Can one of you guys with the intact panels tell me if the panel goes over them?

Hey guys, sorry for the delay. Here's the latest.

I got my pattern cut on the laser! I told my buddy to just cut this one out of cardboard because there will probably still be a few holes I need to move a bit. Since this one will be more firm than just the paper templates, I'll really see if everything lines up.

I plan to cut the real thing out of this stuff: Black Treated Waterproof Panelboard

Upholstery shops use this stuff to make door panels ­ cut it to shape and and stitch the vinyl to it. I've got a sheet of it and it looks a lot like our original kick panels, except the original had a leather pattern slightly embossed into the surface. The closest I've found to that so far is this Coated and Embossed Panelboard (Not Waterproof).

I've heard some upholstery shops have switched to ABS Plastic Panel Board because it is completely waterproof and will not delaminate or warp. Some people say you can laser cut ABS but other sites say that ABS emits cyanide gas and tends to melt!

Anyway, my buddy said he had a few sheets of this other material­­ - ­it's just like corrugated cardboard but made out of plastic! I've seen this stuff used for signs and trade show exhibit stuff. It's lightweight, totally waterproof, and would actually provide some insulation. It turned out real nice!



It looks better than I expected. It's not shiny plastic. The black looks a lot like the panelboard. You do see the corrugation lines but that looks kind of cool too. (click image to see larger):  





And, it comes in different colors!



Read more about it here.

There are a few holes I need to move in my pattern. You can see the headlight openings are a bit too high. And remember, the panel will not be this close to the metal once there is insulation behind it. Maybe that will provide enough room for the speedo-cable and heater core tubes to go behind it.

Also, this is not one piece. This laser can't accommodate a sheet that big. But I tell ya, I had a hard enough time getting the drivers side piece in, working it around the steering column and that support under there. I just have to decide where to put the seam. Or, maybe I leave it like this, where they both overlap. Or we pay more and find a shop with a bigger laser bed. What do you think?

Awsome idea and attention to detail. I love seeing stuff like this become reality. 2 thumbs up!!

Yes, attention to detail. It's a blessing and a curse... I love getting things just right but it eats up a lot of time.

That looks fantastic. Didn't know what I was missing...

keep us posted when and if you take orders ,

Heater core tubes go in front of the panel

Thanks a lot for the photo, Chevbone! That's what I figured, that those heater core tubes had to be on the outside. Strange that the manual would specifically say not to remove the heater, just the defroster vents. I can see how the mat would fit over the heater box, if the heater core wasn't in it!

I gave my laser guy a sample of the waterproof chip board and some jute. The board should be no problem to cut but I'm not so sure about the jute. I'll find out next week. Today I'm making the final adjustments to the layout, based on how the plastic cutout fit in my van.

Update???

Overdue update. I found a few things I wanted to adjust so I did another paper plot to double check the fit. I'm going to do one more paper printout before cutting one out of the chipboard.



My laser guy did a couple of tests cutting through jute. I thought the stuff might catch fire but it did not. It cuts real nice when you get the power setting right. He then did a couple of cuts with the chipboard on top of the jute, cutting through both at the same time. Works great. So the plan is to spray mount the jute to the board first and then cut it all at once. That's going to make it just like from the factory!

Thanks for the update, excellent progress!
Cant wait to order one.

Scott

Me too.

Nice work. I just made one for my passenger side out of thick foam so I used it as my gasket for reinstalling my heater box. Looks nice and finished and adds a little padding up front. Not okay for the uber stock guys but okay for me. Nothing like how well you did yours.

You should be able to sell those, make a few at a time, with each iteration being a little more perfect. You won't get rich with cheapskates like us yet you will offset your costs, get some money for your time, and please people. And, when you have it absolutely perfect, to satisfy your OCD, install that set in your van. I hope you consider so.

Happy motoring, Mark

Any update?

Ok, here's the latest. I made my "final" adjustments to my measurements and then found one more thing I wanted to do. On Leftcoast's van I noticed that his kick panel had some openings that were perforated but not knocked out:





It was because his did not come with windshield washer option. So I just had to add that to my plans! Now, just like the guys at the factory had to do, if your van does have windshield washers, you'll have to cut on the dotted lines.

I spray mounted jute to the back of a sheet of black panel board and gave it and my latest file to my laser guy. I'll let you know when I get it back all cut out!

Thanks for the update, u r really getting close!

I am surprised that the adhesive doesn't interfere with the lasers ability to cut the jute and sheel metal. From what I have seen paper and glue don't mix well with the gasses of a laser and tend to make more of a weld.

any updates?

Thanks for your patience, guys. Mine is wearing a little thin too. First my laser guy was out of town a few times at trade shows, etc. And now I just returned from a week-and-a-half trip. But today he told me he did the cutting while I was away! No problem cutting through the panel, adhesive, and jute! Now he just needs to bring it in and give it to me! I think it is still at his shop. I should get it this week!

My laser guy said the chip board cut very clean. He left it at his shop because it smelled a bit from the laser cutting. And now he went out of town again!!!!!  

Absolutely amazing, great work. I would be interested in one if you are going to market them.

I finally got the latest panel from my laser guy! This is the one with jute spray-mounted to the back of the black chipboard. (It is blacker than it appears in these photos.) The laser cut through the board just fine but it didn't get through all of the jute. Next time we'll try a higher setting on the laser but he didn't want to go too high because the laser can leave a burn mark on the surface. You can see some of that on the close-up below.

So now I need to use a sharp blade to cut the remaining strands of jute to remove the cutouts. More photos soon!

Looks great! u r almost there, u guys r doing excellent work.

Looking forward to finished product.

Scott

A great work you are doing here! We have three first gens that will need this!