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Hi mate,
I did a very similar thing to my 300tdi a couple of years ago, there was rust in the foot wells, I wanted to have a bigger console and insulting the firewall was a very tempting idea as well!
So I guess the biggest part of this job is removing the dash, I started by unhooking all the electronics, gauges switches speakers etc.. Once that's done the top part of the dash (with the ash tray) has to come off first I found, heater vent screws and a couple of others... From there I can't really remember!! It was just a matter of working through the many screws and bolts that attache it.. Can't remember what happened with the vent flap levers either, someone else might?..
Anyway once removed the first thing was the rust, I used a rust converter on all the rusty bits and depending on how much its got you might have to patch some holes.. I had holes from where the old aircon pipes came through the foot well which I sealed with a small square of gal sheet. Once I was satisfied with the rust treatment I painted the whole firewall with black Killrust anti rust paint, once again someone else might have better advice but that's what I decided on.
Now it was time for some insulation, I used dynamat extreme in places on the larger panels and as I was stuck for cash after that I went with those cheap foam camping roles from Kmart, I made sure it was closed cell by soaking it in water, couldn't be to sure haha!
You just have to sort out your own method for cutting pieces to size, pick somewhere and go from there.. I used an aerosol adhesive which was super sticky and worked really well.
Refitting the dash I found was tricky because of the extra 9mm or so thickness of the foam, no real tips on that one just persevere with it! Can't remember which order exactly but I guess just reverse of how you pulled it apart.. Good luck!!
I can't say I noticed any drastic reduction in noise straight away but after doing a weekend long trip to Lighting Ridge (from Geelong) for a mates 21st I could definitely notice the improvement, definitely stops a bit of that Tdi hum!
Right you want a console, I put a fair bit of thought into options for this and in the end based on the skills I had and tools available at the time I decided to make one out of plywood, I used 10mm I think it was.. I was aiming for the look of a puma dash including the round vents up top an all, would look pretty cool and a lot more space for goodies! Sadly I only got half way on that project although unfortunately I had already hacked a large hole in the existing dash! I've now got an RDX XL Console fitted which is pretty much the same look. But anyway I was going to put black vinyl on the ply to make it more factory looking, I found some that matched the Tdi dash pattern.
Its really up to you, I think the raptor console is great and the mud console as well looks practical and the one I've got is great to but if you cant afford it that's how it is, making one is fun and you can make it to suit your needs which is a plus..
Egt gauges... I would highly recommend Thermogaurd Instruments for one, I find the digital display gives an easier to read and more exact reading then an analogue gauge. Also the bloke owns a 300tdi himself and can supply you with an already drilled and tapped plate for the turbo if you need one. Be careful removing the existing plate, the bolts can be very tight/seized (I leant the hard way damn it)!!
Hope I've been helpful, if you've got any particular questions let me know.
Cheers, Remo
Originally Posted by Defendozer
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