Hey guys, I've got a Covan's "Thunder Road" dash panel to go into my 72 Chevelle, sweep dash car. I'm to the point of cutting the old (stock) panel for the new one to fit into, and I was wondering how you guys that have done this cut yours? Any pictures? Any hints? Thanks in advance!

I`m doing the exact same thing with the Covan`s dash. Anybody done this???

I used a jigsaw.

I used a dremel, didnt' want to use a tool that might damage the dash in case it got caught up ,I didnt' cut a covans but I was cutting in some ac grills for a vintage air system into metal and plastic parts . JOHN

I'm also installing a Covan, how did it go with the cutting ?
I thought I didnt have to cut anything :)

I used a Dremmel with a cut off wheel. It more or less melt the plastic but worked just fine for me.

I used a Dremmel with a cut off wheel. It more or less melt the plastic but worked just fine for me.

Didn't have to cut anything on mine (I have a 64) accept the whole for my stereo & I used a cut off wheel for the majority & hand sawed for the corners!

Covans are crap. I installed one in my friends 70 Chevelle. Poor fit and way to flimsy for my taste. Just my two cents worth.

Cruzin, Was it the old "covans classic dash" or the new thunder road dash? from the pics the thunder road insert looks a whole lot better. (just curious)

As far as Covans being crap (respect your oppinion), but I just installed the new style in my 64 & the fit was OK, not the best but simply fit aswell as any other aftermarket part I've ever used & it actually fit pretty good after fudging it a little...I gotta say though it seemed a little flimly taking out of the box but when I got it installed for good it's solid as can be & I really like it! I realize some will say if ya pay good money for something that you shouldn't have to mess it, this just isn't the case with any aftermarket piece I've paid good money for...well atleast most of it, lol! Man I've tried alot of stuff that I've ended up just throwin it away it pissed me off so bad! This new Covan thunder road dash in my experience is a nice peice! FWIW.

Chad,
Can you post a few pics of it?

Chad,
Can you post a few pics of it?


I'm retarded with computers...only way I know how to post pics is by attaching as thumbnails & it won't let me upload those pics again cause I already did in a previous post? Just go to my profile & look at the current project album...there are about 5 pics in there that show the covan thunder dash!

Thanks,
Looks good; nice albums.

I finished installing mine today, I had sweep dash, and didnt cut the old one out, after removeing the old cluster gauge, I just placed the Covans on top op the old one.

I used a die grinder with a 2" disk and 1" drum pad. Worked a treat :)

The BEST tool for cutting these dashes (and just about anything else that isnt metal) it the multi-tool they sell from Harbor Freights. It is usually on sale for $39. It cuts throught plastic with ease - little mess and a very thin clean kerf. I strongly suggest it. It is a knock off of a much higher priced German tool, I cant recall the name right now, but this one works just the same. There is also now a Dremel version avail at Home Depot if you are not near a HF. I love mine and use it for everything - so it is a good investment!

The BEST tool for cutting these dashes (and just about anything else that isnt metal) it the multi-tool they sell from Harbor Freights. It is usually on sale for $39. It cuts throught plastic with ease - little mess and a very thin clean kerf. I strongly suggest it. It is a knock off of a much higher priced German tool, I cant recall the name right now, but this one works just the same. There is also now a Dremel version avail at Home Depot if you are not near a HF. I love mine and use it for everything - so it is a good investment!This one?

http://www.harborfreight.com/media/catalog/product/cache/1/image/370x/9df78eab33525d08d6e5fb8d27136e95/i/m/image_2040.jpg

I got the Covan's Thunder Road panel w/ American muscle gauges. I used a dremmel to cut the original where needed. I tried to maintain as much of the original dash as backing to ensure stability. I also used epoxy to bond the Covan's panel to the original dash (it came out so secure I didn't even need screws but I put them in anyhow). Here is it step by step (I've included links to pictures of my dash step by step).

Part I
The Panel as it arrived:
http://img534.imageshack.us/img534/9952/0429001643a.jpg
http://img175.imageshack.us/img175/2281/0429001643b.jpg

Where you will need to cut before attaching:
http://img683.imageshack.us/img683/7816/olddash3cut.jpg
http://img62.imageshack.us/img62/513/313060414fullcut.jpg
http://img706.imageshack.us/img706/4421/0429001515.jpg

Remove as much of the paint from the original dash panel as you can with lacquer thinner and sand paper and scuff the back of the Covan's panel with sand paper to make good contact surfaces for the epoxy:
http://img197.imageshack.us/img197/8952/0429001725.jpg

Clean both surfaces with denatured alcohol and apply the epoxy:
http://img268.imageshack.us/img268/8207/0429001726.jpg
http://img256.imageshack.us/img256/4818/0429001728.jpg

Place the panel in place, secure it with clamps, and allow the epoxy to cure overnight (make sure you have already checked for a proper fit as my covan's panel requires some minor cutting to ensure a good fit):
http://img64.imageshack.us/img64/4663/0429001734.jpg

The next morning your new dash will be stronger than a brick sh!thouse and ready for you to cut the signal light and radio holes (I recommend using the center line of the gauge holes as reference to ensure consistent drilling):
http://img179.imageshack.us/img179/3236/0430001548.jpg

Also take this opportunity to check for any minor adjustments you may need (I had to trip the top front of the covan's panel to fit the dash pad properly, file the mounting bracket of the driver side vent to make room for the gauges, and trim a bit more off the dash to make room for the new headlight location):
http://img227.imageshack.us/img227/5061/0430001716.jpg
http://img200.imageshack.us/img200/63/0501001201.jpg
http://img709.imageshack.us/img709/5555/0501001200.jpg
http://img22.imageshack.us/img22/2193/0501001210.jpg

Now your dash is ready for paint (I used black satin as it gives the unit a slight armor-all looking finish). Some might not like to paint their dash but I believe it gives it a uniform look which I prefer:
http://img227.imageshack.us/img227/5061/0430001716.jpg

After allowing the pain to cure overnight, your can install your instrumentation:
http://img62.imageshack.us/img62/6880/0501001404.jpg
http://img291.imageshack.us/img291/3402/0501001302.jpg

Nice write up! Thanks for that.

Alex, thanks for posting all those pictures & step-by-step! I've almost finished my project, when I first started I thought you cut a whole section out of the dash and replaced it with the Covan's (didn't realize it was an overlay). If I'd seen your pictures then I could have saved some time and $$$ but hopefully this will be there for the next guy :)

Yes, that is the tool. Everybody is making one now, but the HF model works great especially for the price.

Great thread, found it after I started mine however I did it the same :)

What epoxy did you use for the installation?

It was a 3M product I got from Home Depot. 3M Structural Adhesive (Part #051135-08101)

That really was a good step by step. I wish some one had done that w/ a 72.
I have a 72 El Camino SS w/ the one piece plastic dash carrier and round gauges. There are multi things broken on the dash so the entire thing has to be replaced.
The best I can figure out is that I'll have to buy a sweep style dash carrier to start with. I believe the gauge cluster in that style dash carrier comes apart from the carrier. Then I 'believe' (haven't confirmed this yet) I can use the Thunder Road SS round gauge cluster to replace the old sweep gauge cluster.
If anyone out there can either confirm or deny this, I'd sure appreciate the feedback.
And BTW, I'm going to search out the Dremel multi tool. That sounds like a tool I can use. I know the Dremel sure has come in handy on many occasions.

You are correct that on the sweep style dash, the guage cluser is removeable. However, there are a number of differences between the sweep style and SS/Monte Carlo style dash that would makes the thunder road inserts incompatible with one another. To address this issue there are two versions of the thunder road overlay (one for sweep style and another for the SS style). Both versions of the thunder road panel are designed to be used with standard aftermarket round gauges. The only difference between them is the mounting procedure to the dash and the gauge orientation on the overlay. Personally, I think that the layout on the sweep style thunder road insert is nicer. If you are looking to buy a new dash to install the sweep style overlay you can buy any dash designed for a 70-72 chevelle, malibu, or el camino and follow the write-up above. Below is a picture of my completed sweep style overlay that I put on a '70 malibu dash that I then installed in my '72 chevelle.
http://img855.imageshack.us/img855/5928/interiorf.jpg
http://img94.imageshack.us/img94/2058/guages.jpg

I actually found a picture of the SS insert online which I am including below. Since the SS style dash comes stock with its own overlay (this was designed to differentiate the SS - black vinyl insert from the Monte Carlo - polished wood insert), the SS style thunder road simply replaces this insert with some minor modification. Below are a picture of a standard SS/Monte Carlo Dash and the corresponding thunder road overlay.
http://gmsportssalvage.com/files/images/IMG_9295.preview.jpg
http://fastlanewest.com/store/images/70-72%20Chev%20SS%20CF%20CFE.jpg

Thanks for the feedback and info. That's what I needed to know.
I'm going to Carlisle this coming weekend. I'll look for a sweep replacement dash carrier.

Wow! I am in love with your dash bigman. Looks awesome.

Covan didn't appeal to me so made due with the original dash and tweaked it a bit.

http://i113.photobucket.com/albums/n220/Nikoda2002/garys%20new%20super%20size%20pics/IMG_2428.jpg
http://i113.photobucket.com/albums/n220/Nikoda2002/garys%20new%20super%20size%20pics/IMG_2411.jpg

I used a dremel tool .... worked great !

bigman1425, I assume you already had your radio when you cut the hole for the radio? Otherwise, how would you know the size to cut.
I went to Carlisle and walked the entire 150 acres looking for a sweep style dash. Everything I found was cracked beyond repair. But I did buy one off Craig's list on my way back home. It's in good shape and hopefully I can install an insert that will look as good as bigman1425.

Here are som pic. of my Covan dash with Autometer Cobalt gauges



http://www.r-k.dk/covan1.JPG

http://www.r-k.dk/covan2.JPG

http://www.r-k.dk/covan3.JPG


http://www.r-k.dk/covan4.JPG

http://www.r-k.dk/covan5.JPG

Dr. Pepper, yes I did already have my radio. However, I believe all aftermarket radios follow the same size specifications (either single din or double din). You can make your hole based on those specs though the housing plate may vary slightly from manufacturer to manufacturer. Also, I found it helpful to include additional support by riveting an aluminum brace to the supplied retainer.
http://img22.imageshack.us/img22/2193/0501001210.jpg

Killer, love the backlit 383 plate. Did you make it or buy it?

A friend made the plate for me, then 1 led in each end.