Dashboard Upper

Description

The dashboard upper is the critical part where the windshield and steering parts are installed. Position the dashboard upper properly and secure it by MIG welding.





Mass Production Body Welding

Replacement

1. Remove the related parts.
- Wiper arm and wiper motor
- Windshield
- Right and left front fenders
- Front pillar trim panel
- Door opening trim
- Hood
- Parts related to steering column
- Dashboard, etc.

2. Pull out and straighten the damaged area.
- The collision damage may extend to the front pillar and roof panel (coupe) and roof rail (open top). Check for the damaged sections carefully and pull them out to reshape.




- Before pulling out the damaged sections, it might be necessary to heat the sections with an acetylene torch .




3. Remove the dashboard upper side extension.
- Strike a punch in the center of the spot welds.
- Drill the spot welds using a 10 mm (3/8") spot cutter.
- Grind the MIG fillet welds using a rotary cutter.
- Remove the dashboard upper side extension using a chisel.

4. Remove the dashboard upper.
- Drill a punch in the center of the spot welds to the dashboard lower, front wheelhouse, and front pillar.
- Drill the spot welds using a 10 mm (3/8") spot cutter.
- Grind the MIG fillet welds using a rotary cutter.
- Remove the remaining welding flanges using a chisel.
- Remove the burrs from the drilled flanges using a disc sander.









WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

5. Mold the related parts.
- Reshape the welding flange of the dashboard lower with a hammer and dolly.






NOTE: Check the reshaped parts for cracks.

6. Set the new dashboard upper.
- Drill the 8-10 mm (5/16"-3/8") holes for plug welding in the welding flange of the new dashboard upper.
- Remove the undercoat from the both sides of the welding section and expose the aluminum alloy base using a disc sander.

WARNING: To prevent eye injury wear goggles or safety glass whenever sanding, cutting or grinding.




- Remove the paint film from the welding section of the body, and clean oil contaminations with a shop towel soaked with wax and grease remover.
- Before setting the new dashboard upper remove the oxide film from the welding section of the replacement part and body using a stainless steel wire brush.
- Set the dashboard upper and clamp it with the vise-grips and pliers.
- Install the windshield and check for proper installation and alignment.
- Check the body dimensions.
- NSX-T (open top): Keep the body level. Check the front roof rail and door opening position using the roof panel positioning jig recommended.

7. Tack weld the dashboard upper. Plug weld the clamped sections.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

8. Remove the vise-grips and pliers and install the front fender, windshield and hood. Check for difference in level and clearance.

9. Perform the main welding.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.







- Before welding, perform the trial welding following the welder manufacturer's instructions.
- Remove the oxide film from the welding sections using a stainless steel wire brush.
- The applicable welding methods are MIG welding, plug welding, and fillet welding.
- Check the welding sections for cracks.




- Weld the dashboard upper side extension.

10. Finish the welding section.
- Roughly grind the welds with a disc grinder. Be sure to leave the finishing allowance this time.
- Finish grind the finishing allowance with a disc sander until it is smooth.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

- Smooth the mating surface with the front windshield with a hammer and dolly.
- Take care not to grind the aluminum alloy base while roughly grinding the welds.
- Take care not to grind excessively.
- Do not press on the sanding tools excessively. If the disc face is clogged with the aluminum alloy particles, replace with a new disc.

11. Apply the sealer.
Apply sealer to the upper dashboard, pillars, etc.

12. Apply the paint.
See Paint Repair section.

WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.

13. Apply anti-rust agent to the inside of the dashboard upper.

14. Install the related parts.
- Install in the reverse order of removal.
- Check the front fender and hood for difference in level and clearance.

15. Inspect and clean.
- Check the windshield for water leaks.
- After installing the dashboard, check the lights, gauges, etc. for proper operation.
- Clean the interior.

NSX-T (open top):
- Set the roof panel, then secure the roof panel by turning the roof side lock handles.
- Make sure the roof side locks are locked securely.
- Check for water leaks.