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SUPER ROD VISITS JUST DASHES
Jeff Tann is covering the restoration of a 1979 Pontiac Trans Am center console.
By Jim McGowan
Super Rod, a publication of Buckaroo Publishing, visited Just Dashes to create an article on the restoration of a well-worn center console. Jeff Tann, a seasoned magazine editor, car builder and restorer, spent a morning with us to discover how we work our restoration magic. Jeff had never witnessed the Thermo Vacuum Forming process and was amazed at the amount of work involved in first preparing the part and then recovering it with vinyl. This console had been seriously abused over its many years of use. It literally had gouges and deep scratches in the top surface and the sides were all but collapsed from the driver leaning on it while entering and exiting the vehicle.
This console even taxed our claim of "no part too difficult to restore". The damaged vinyl was sanded smooth and the sides reinforced. A layer of high-density closed cell foam was installed on the entire surface of the part and then hand sanded for a perfect shape. In preparation for a new skin of the correct grain vinyl, a coat of professional grade adhesive was sprayed on the entire surface. The part was then installed on the machine and prepared for the vacuum process. This is a critical step because if the item is not correctly supported, the vacuum pressure could collapse it while installing the new vinyl. Obviously, the process was a success as usual, and the final product our usual concours quality. As with all our interior restoration finished products, the console was then dyed the correct interior color. Watch for the complete article in an upcoming issue of Super Rod.
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After preparing the console surface, a layer of high-density closed cell foam was applied to the console and hand shaped to perfection. Expert handwork at this stage is the key to a quality finished product.
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The surface of the foam is then sprayed with adhesive to bind it to the hot vinyl during the vacuum forming process. The glue must be applied very evenly for a completely level surface. The slightest imperfection will show from under the new vinyl skin.
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The console is installed on the Thermo Vacuum Forming machine and prepared for recovering. Every nook and cranny must be filled around and under the part to provide support so it doesn't collapse under the pressure created by the vacuum.
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Jeff is waiting for the vinyl to come out of the heating oven to capture the process in pictures. It happens very fast, so being ready and in a good location is critical. Using a stepladder allows him to shoot over the heads of the Just Dashes workers.
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The machine is now sucking the hot vinyl down over the console completely covering the exterior. After the vacuum is shut off, the part is sprayed with water to cool the part so it can be removed. This process takes only about 30 seconds. Most of the production time is consumed in preparing the part for recovering.
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The console now goes to the hand finishing area. The vinyl is glued around the edges and the restoration process completed. From there it's on to the quality control area.
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The last stop is the coloring department. Any item, like this console, that requires a color other than black, is dyed the correct factory color for your interior. Once dry and quality inspected again, it's carefully packed and returned to the customer, usually by UPS.
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While this is not the console, it is a heavily damaged and deteriorating dash pad. This photo shows the lengths the Just Dashes craftsmen will go to save an original pad. All the dried and flaking foam is being removed prior to adding a new layer of state-of-the-art foam.

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