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morghen · Joined: 21 Jan 2005 Posts: 9044 Location: Romania

Well scan has some small tolerance, then plastic warps as it cools down, and then the dash may be twisted ik the car with your design being straight.
Those things can generate weird gaps.
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Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

All good points. I think its best I try a couple other dashboards before I drive myself crazy.
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car

morghen · Joined: 21 Jan 2005 Posts: 9044 Location: Romania

Also, i’m guessing you designed the visible surfaces to match with the scan of the dash, but what about the orientation of the 4 feet? You may have an issue there, maybe remove the rubber things in the dash that holds the part and see if your part fits without that constraint.
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924RACR · Posted: Fri Jan 17, 2025 6:42 am Post subject:

If you want to do a compare test fit against a new dash, I can stick it in my car and take pics... (I also have two rather old abused dashes, maybe 3, across the cars and storage, which could be compared to)

That said - honestly I don't think the shape of the new dash is any different than my old dashes, so I don't think this will give you any different answer.

morghen has a good point re: the foot orientation - should be able to cut off the feet from a failed attempt, see if the answer is any different...
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

I would lean more toward your warping idea than the feet. By putting the window on the middle of the panel so I could see everything underneath, its weaker and therefore gets affected by the printing process.

Pins are spot on every time which is actually the cool part. Just slides right in. They were modeled straight from the speaker cover not the dash since I don't trust the dash as much. The dash I am using has been inside in storage since '91 but I am gong to try some others

Every time I print a test piece I have adjusted the four corner radii. The edges fit good top back and front bottom. Its just the curvature that is not as nice. Really could be what you say

_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car

morghen · Joined: 21 Jan 2005 Posts: 9044 Location: Romania

Well, the dash may also be warped. The material of the original part has some mechanical properties and the 3d print has different, in my experience it is normal to have a slightly different design for a different material.

In regards to the part warping, you can always 3d scan your 3d printed part to check for deviations and either confirm or rule that out.
_________________
Supercharger and EFI kits
https://www.the924.com

Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

Kenodog · Joined: 25 Jun 2003 Posts: 2667 Location: Vancouver,B.C.

I have a new dash from Werk924 I would lend you if you lived closer...
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1979 Euro 931, Olive
1981 931, Sabine
1991 Ford Ranger XLT 4x4, Ricky
1996 Ford E-350 ex-FedEx Van
2014 Mazda CX-5 (Kinderwagon)
2019 KTM 790 Adventure
2024 KLX300
2024 KLX140

924RACR · Posted: Sat Jan 18, 2025 2:36 am Post subject:

I have the new dash from the dealer, as well as 2-3 used/original dashes, to test fit against...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

When I get one I like fit wise I will hit you guys up. Kinda neat you two have one of each

Thanks!
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car

Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

I think you guys can see the numbers. Extruding curves straight along the horizontal length. Curves are also made with tolerance to the original as I create them then extrude with the extrusion tolerance being shown in the pic.

I then set the extruded surface/curve in yellow under one of the CAD models. For me, my favorite part are the pins, since they just fit. I'll figure it out. Just wanted you guys to see.

_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car

Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

It was the dashboard! (Morghen

, thank you!! ...I just didn't think my '80 dash was that bad. I was wrong)

Crawled up into the '82 getting other work done on the lift. (halfshafts, brakes, custom exhaust). It was the Dash in my '80 all along. Of course, this version 4.75 I call it, had a part of the original CAD model left out as it transferred between programs. Got to love it (and be more observant before hitting print button). Going to finalize and get it printed in SLS as well

_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car

morghen · Joined: 21 Jan 2005 Posts: 9044 Location: Romania

Awesome! Are you going to make a symetrical version as well or just keep the original idea?
_________________
Supercharger and EFI kits
https://www.the924.com

924RACR · Posted: Sun Jan 26, 2025 12:23 am Post subject:

Sweet! Much want...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Mike9311 · Joined: 14 Dec 2004 Posts: 1793 Location: Chicago-ish

Thanks guys!

Knowing me I will make several versions

Its a parametric model mostly, so when I try something, I create a new version copy. They then evolve into something else. It starts when I think "oh let me change this fillet" and then that fillet has me making other changes

Seriously though, I originally wanted to see what a 3 gauge pod would look like. It was something I have been thinking about for a few years after getting a larger VDO EGT gauge as a gift. Not sure if that part of the idea will be tried but I still wonder about how three would look. Or even a single clock. The clock always gets pushed out

I will make a right facing mirror copy of this one and a straight version. In all of them I like some type of top shade to cover the gauges from glare

Vaughn, I'll PM you. I'll send you one to try and also to critique (please do, anything and everything). You are relatively close
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car