What can be done about a radio hole that has been butchered? I'll probably end up putting a gauge panel there, but was thinking how nice it would be to have a pristine radio hole again. What do most guys do?? This is in my 72 Malibu by the way. :)
Chris

How hacked is it? Big enough that a DIN style modern deck will fit and cover up the damage around it?

I have actually walked away from cars because of this. I'm really an advocate for original radios.

If it isn't too bad, you can tack weld little pieces of similar gauge metal to repair it. The real effort here is cutting the metal pieces just right and the positioning of them, before tack welding.
I did this to repair some elongated holes in my chevy truck.
I think I even tacked a weld or two at the corners of the rectangular opening to get it just right. Take your sweet time here and use a file to shape the welds.

I think the only time anyone will need to replace the whole section is in very extreme cases.

Tha panel in the '72 is plastic and it might be possible to find an unhacked panel and cut out the radio area, glue it in and repaint. I looks like a lot of work to do that. (Yep, I have 3 chevelles all with hacked radio openings. )

I know that the dash immediately around the gauges and radio are plastic, but there has to be some metal behind it.

I find it hard to believe that the front of the radios are weighted strictly on the plastic. If this is the case, I would just replace the plastic.

The dash around the radio is plastic.The radio had a brace behind it for support. If you can find a dash with unmolested radio knob holes it's probably easier to change whole dash. The lighter in my 70 shorted and melted the dash plastic around it and trying to repair that hasn't worked out the way I'ld hoped.

I cut out my radio area (1970 SS dash, original..) and kicked myself every day since. I should have installed it under, and left the 8-track face plate at a minimum in the hole.
I talked with a few interior and body/paint guys, and the general consensus is that its a difficult or impossible fix. I even bought a repro dash, that sits in the garage now because its too 'cheezy'. I keep my eyes out for a 70SS dash, but no luck locally so far, a local guy does a great job rehabbing them here. Sorry to hear you are in the same boat..

matt

I know that the dash immediately around the gauges and radio are plastic, but there has to be some metal behind it.

I find it hard to believe that the front of the radios are weighted strictly on the plastic. If this is the case, I would just replace the plastic.

This is true. The back end of the radio is supported by the metal structure in the dash. The plastic face could never support that weight. Without the support at the rear of the radio, rotational force would tear it out of the dash the first time you hit a hard bump.

But the plastic does a good job of supporting the front of the radio. With the back supported, there are only shear forces acting on the plastic. What you have essentially is a three point mount.

Here's what I did on my 70. Took a piece of textured plastic and cut it to fit the recess in the dash then I cutout for the DIN style radio and added 3 1 1/2" gauges. The two on the right are angled towards the driver slightly. Turned out alot better than what was in there.

LK

http://xs205.xs.to/xs205/06331/70-radio.JPG (http://xs.to)

Sweet Job,..... Alwhitie

My 68 has the same problem. Your idea looks perfect!!! Thanks

Tony

This is true. The back end of the radio is supported by the metal structure in the dash. The plastic face could never support that weight. Without the support at the rear of the radio, rotational force would tear it out of the dash the first time you hit a hard bump.

But the plastic does a good job of supporting the front of the radio. With the back supported, there are only shear forces acting on the plastic. What you have essentially is a three point mount.



I did consider the rear support, in fact, I dont think there is a radio without one..even with an all metal dash.

I still think stress cracks would occur without at least incorporating a reinforcement plate between the radio and the plastic to help distribute the stress.
I know I've seen some plastic dash cars with this plate.

Maybe the front of the radio is designed with a large enough flat area to mate up to the plastic sufficiently.

...whatever.

Replacement radio towers are available, I got some about 9 years ago, don't quite remember who I got them from but it was from someone here on this forum.

I have a super nice 72 Chevelle SS dash if someone needs one of them, never been cut on and perfect radio holes, does have a cutout for rear window defogger, this one has the seat belt warning lamp and this one came from a SS Chevelle, not a Monte.

Gibby zrwonder@comcast.net

There's a shop that sells on eBay, I beleive the name is Audio Adapters, that sells non textured black plastic that looked like it would work like the above fellow did it. I'm not 100% sure if that's the name of the company (I'm 95% sure) but I bought a power door lock kit from them. So if the name isn't quite right, look for the PDL kits and go to thier online store. That's how I found it.