Safer underdash trays

I have never been happy with the sheet steel under dash trays in the GD. In an accident they could be like a blade to the legs or body, stiff and sharp. Ouch!

Metal under dash tray

So, I have decided to replaced them with hardboard, which should give a bit on impact as it is a less stiff material and is more compliant. But hopefully I will never need to test this out.

First I marked lines on the existing trays to show how far they went between the cross braces and dashboard. This material needs to be removed from the new pieces. The two steel trays were then removed and used as templates on the hardboard. The shapes were drawn round in pencil, including the heater duct vent and 12v power outlet. Then the new trays were cut to this line, not forgetting to remove the strip that goes between the dashboard and cross brace. The fixing holes were drilled and the edges rubbed down with sand paper.

New under dash tray cut out from sheet

Each new tray is located by two thin metal tabs (see photo below), which I had fabricated. These tabs are bolted to the tray, then locate between the cross brace and the dashboard. After reconnecting the heater ducts and the 12v power outlet, the trays are then fixed in place with two screws at the front.

Tray fitted. Note the fitted tab,12v outlet and heater duct nozzle 

The trays could be painted if required, but I have decided not to do this. The change is simple and would have been a cheaper alternative to the laser cut steel trays! Also it should be much safer too.