Replacing centre dashboard binnacle

gazzah

Member
The top of the console in the centre of my dashboard completely disintegrated, the plastic got so brittle from heat & humidity it cracked, and attempts to repair it just made it worse until in desperation I cut what was left off to see if I could get a 3D print to replace it, but turns out that needs a whole piece to get a scan.
There is a complete dash available in the UK but freight is ridiculous, over 800 GBP for a 95 GBP unit.
I've asked the wrecker if they can cut away the majority of the dash, leaving a bit around the edges of the console to protect the little lugs I found when taking the top off. That should make for a much less bulky package so freight should be bearable.
My question is about the passenger side airbag, is that in the little handle thing that sits above the glovebox? Does it need to be disarmed before undoing the screws inside the console circled in the attached photo?
 

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The airbag sits beneath the plastic of the dash underneath that handle, above the glovebox, so well out of the way of the handle and no dependency.

@timmus would need to confirm (who has removed dozens of dashboards) but IIRC the dash comes out whole, including the handle. However if you're only going to get the centre section, the handle will have to be removed or cut through. I believe it's metal inside, and I think there is also a metal plate that runs under the plastic top of the dash in places.
 
Hi Gazzah,

I’m sorry to see this has happened. It’s an increasingly common problem in hot places. Dozens of A2s in Italy have suffered the same damage.

The dashboard is one whole piece. The centre console is plastic welded to the rest of the dash. Although the centre console is therefore not designed to be replaced separately, it can be done. However, this requires the whole dashboard to be removed and flipped upside down. The plastic welding can then be carefully removed such that the existing centre console separates from the rest of the dashboard.
The replacement centre console (which must have been separated from its ‘parent dash’ in the same manner) can then be attached to your existing dash, using your preferred fixing technique.
The newly repaired dashboard can then be reinstalled in the vehicle.

Unfortunately, the whole process requires intimate familiarity with how the A2’s interior is (dis)assembled.

Is now a good time to remind you that I have an Australian passport? ?

All the best,

Tom
 
That doesn't necessarily mean that you can get there at the moment though! Unless things have changed.

RAB
Indeed, I believe I still wouldn’t be allowed in. Though I suspect this is wholly academic.
 
Is your bag of bits enough to make the complete area? If so why not reassemble that and get that scanned and 3d print it a bit bigger to allow trim to fit. Another alternative would be to make a mould from it and remake the part either in glass fibre or carbon fibre. Failing to get a replacement dash this is the route I would go down.
 
Hi Tom, sorry to say the borders between Western Australia and the rest of the world are still firmly shut until we reach over 90% fully vaccinated, projected to be some time in January next year. In the meantime I'm negotiating with Prestige Auto Parts in the UK to hack a replacement out of a dash they have in stock leaving a few inches of the old dash all around so I can finesse the fine little tabs and bits away from the substrate of it's old home.

I did try to get a local expert - calls himself the Shapenerd - to 3D print a replacement, but the time & effort required to reassemble the jigsaw that is the top of my old console, scan it, print it, colour it and reattach it to a precarious remnant that is itself crumbling would cost more than the 275GBP (180 of which is freight) for the original item from blighty.

Same problem goes for making a fibreglass or carbon fibre replacement, the remainder of the shell is too unstable to attach anything and getting an exact join is nigh on impossible. The remnants of the console have cracks that are only being held together by the paint.

There are some screws for that handle that attach it to a metal frame that sits inside the console, so if there's no need to disarm anything hopefully that will be OK.

The Shapenerd tells me the console is made of a very unconventional mix of polycarbonate & PET (recycled Coca-Cola bottles), and is very difficult to weld or glue, which is why the heat affects it so much, heaven knows why Audi chose such an odd material. I think they only want their cars to stay in service for a few years, then they want you to throw them away and buy a new one, so they give very little thought to longevity or ease of maintenance. That is evident in all sorts of issues I've had resolved by folks on the forum, like the glovebox lid opener and light switch, the fuse cover clips, the soft finish on the switches...

Thank heaven for this forum, the people on here are so helpful and clearly enthusiasts.
 
I have a centre section of the dashboard. It’s a single din unit. The rest got damaged in an accident and I carefully removed the centre part. It’s in black.

Let me know if any good.

Chris
 
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