I purchased these Diablo defrosters
from Jason at LamboStuff.com
These
are photos and comments from other builders about there installation methods.
There
is a detailed "manual" that Dale has created for you to view
(in regards to this section). This instruction manual is on how he built
his IFG Phantom Roadster. (click on his logo to visit
his web site)
Defroster Duct Pattern
This is the pattern for which the defroster duct will be made from. I
decided to have an operational defroster system. However, the small clearance
does not allow duct hoses to be used. This is the only way I can see to
duct defroster air - by making and bonding an integral duct to the dashboard.
Defroster Pattern
This picture shows how the defroster air will be routed to the defroster
registers (grills). The defroster vents are slightly on an angle to match
the curvature of the windshield lip.
Out Of The Mold
This is the defroster duct out of the mold, cleaned and painted. You only
need to paint the inside since you need an unpainted surface when you bond
the duct to the dash.
Defroster Duct Bonded
The defroster duct is then bonded to the front piece with Fiber Strand
and fiberglass. I made alignment tools from wood to fit the duct in the
proper place. The tool mimicks the defroster duct register (grill). In
addition, I bonded some speed nuts so that when the registers will be
installed, they will be held in place.
Front Dash Installed
The front part of the dash is now permanently installed. At the fron corners,
the piece is bonded and screwed in. A 1 inch steel flat bar is bonded to
the underside of the piece and welded to the A-pillar. I also made alignment
pins so that the main dash unit will be properly aligned with the front
piece. The only thing left to do on this piece is to fill the gaps. In this
picture you can also see the defroster duct that was bonded to the front
piece.
Designing the Duct
This picture shows the underside of the dash and how the integral duct will
be routed. I decided on an integral duct since, in some places, it will
be difficult for me to route the 3 inch hoses. All ducts will be slip-fit
to the main heater/AC unit plenum.
Making the Pattern
This shows how the dash vent duct pattern is being made. It is made of sections
glued together. The areas where the round Diablo vents are inserted area
extra deep to accommodate the their depth into the dash.
Pattern Complete
This shows the completed pattern as it fits inside the dashboard. It was
painted to provide a smooth surface for glassing. Mold wax is then spread
all over the pattern and fiberglass layed over it on a flat (waxed) surface.
Out Of The Mold
This picture shows the heat/ AC vent duct out of the pattern. It is being
cleaned up for air holes, etc and is now ready for painting.
Although my information
comes from various builders and sources, if you want any information
contact me. The photographs used on this site are used with permission,
if you want to use any, contact them through the various links on this
site. I did and you can see the results!
