Update on the dash assembly: got the frame all measured and fabbed up - tweaked to fit correctly. The frame contour follows the underside rear edge of the hood (as close as my tooling will allow for bending the 3/4 inch tube) to try to minimize the gap. It incorporates a center 'waterfall" frame section that attaches to the floor crossbar next to the center tunnel. (My center tunnel is 3 piece - my mod - and can still be removed with the dash frame installed). I added a curve to the top of the 'waterfall' tubes to add a more esthetic look:
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I then fabbed up the dash panels from 16 gauge (0.060 inch) steel - won out over fiberglass - and easier for me to work with. I welded threaded plates to the dash frame to bolt the dash panels on and to allow removal to work on guages and wiring:
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I added a small 'cubby' at the bottom of the 'waterfall' panel, no room for a glovebox in the dash. The ignition switch will be mounted here for my convenience:
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Next up is to cut holes for the steering column and dash gauges. The odd size/shape of the Cobalt gauge panel will be a challenge - measure 200 times, cut once.
BTW, the stacked washers in the dash screws are there because I need to shorten the screws to 3/8 inch to fit without hitting the frame bars.