Rather than spend $400+ dollars on another used dash, and since there are no aftermarket dash caps available, I dove head first into a shallow pond and decided to repair ours. If you are familiar with these dashes you'll notice how much expanding foam has been removed from the backside of the dash, and the whole dash has been trimmed back to make room for any repairs and for general clean up (again very dirty/dusty back there).
The gashes and warps were ground down, picked and beveled out, small holes drilled out around the perimeter of the gash to make for fingers to allow the fibreglass/filler (50/50 mix of short strand and plastic body filler) to hold it together, and finally a coat of straight filler. There is also a small piece of MDF added to strengthen a very well shrunken/swollen section of the middle dash.
The speaker holes are filled to be drilled out with a hole saw to fit the new taller coaxial Polk 3.5" speakers; there are some screens on order from China to hide them. This will be done after the top of the dash is done being capped with fibreglass sheet (currently curing) to prevent future splitting.
And then more filler... I hate doing body work.
It will be finished with Duplicolor Truckbed coating and some Duplicolor black vinyl paint.
