Perhaps get some aluminium cut to size, cut new holes to suit & get it powdercoated. Only being about 3-4mm thick it wont stick out too far.

cheers Rob

The cheapest option that looks good is simply to face it with some plastic.

Chivers did some glass patch work for me on the old tub and it was fantastic.  Couldn't tell it was patched, the colour match was just spot on!

if your handy go see these guys and get your plastic the will sell you small quants  then mount the new equip to the plastic then the plastic to the dash

i did it on my boat i bull nosed the edges with a router and it looks good

http://www.plastral.com.au/index.php

Get some marine ply to cover the lot and cut new holes in it, give it a good seal then a couple of coats of top quality clear varnish. You can screw straight to the glass dash or from the inside to hide the screws.

Extend it up a bit passed the edge to make a lip so your gear won't slide off the ledge.

would be a slower process but then you'll be left with a clean dash board. The repaired areas will always stand out though because of the new and aged gell/flow coat . i like carnovites idea and you could apholster it as well.

Maybe this would work? My dash had a peice of poly product, great idea as if you what to change any electronics or gauges just replace the poly. Note the throttle is mounted to the aluminium.

Thanks Fellas,

Will probably see what the Plastic fabrication mob have to say about the templates.

I need to try and have one piece bend from the top vertical section down to the flat bit, or I'll end up with a gunk-trap between individual panels.

The bottom section covering the old radio holes will be a separate panel.

Ideally I'd like 1 piece, but the chances of getting it to fit with 2 bends an no square corners will be a PITA.

CCC's option is ideal - a nice semi-recessed removable panel.

Reckon you could fit at least 3-4 new gauges or other components in there though CCC ! 

I thought fiberglass was only a real bitch to fix if you had access only to one side?

You would be working upside down, but probably not to hard to do a good job there doing a regular glass repair.

Thought I'd provide an update :)

Decided to go with the panels.

I laser measured all the fascias using my survey gear and whacked it into our CAD package. (Computer-Aided-Design)

(Would have been a bitch to do any other way - there's not one parallel side on any panels........ plus the port / starboard sides are not mirrored)

Printed out some full size paper copies for checks - they fit great first time up.

Contacted the plastics mob and can just send them the CAD file for CNC production of 6mm Acrylic or PVC (haven't decided yet) with nice bevelled edges.

Saves dicking around with templates !

Looks good, post up some pics's of the CNC panels when you get them.

CCC

Thanks, Will do.

Boat's in getting glass screens fitted - panels should be ready by the time it's back.

Well, after getting the new glass screens fitted, I finally got some time and got my ass into gear today to fit the dash panels.

Ended up using some ridiculously strong 3M double sided tape (thin film, not spongey stuff) to provide the "clamping" and hold it all in place, with a few beads of Sika in the middle and edges to seal the perimeters and make sure it stays on.

Worked a treat - very glad I chose not to go with the screw option - just got to make sure I don't screw it up when drilling !

(It was more fate than anything, as Coventrys Osb Pk was out of stock and I couldn't be assed driving over to Welshpool to get the stainless Button head allen key screws I had planned to use.)

Got the panels on early, so Sika was well and truly stuck by arvo - then got keen and fitted the new Hydraulic Steering Helm, new Simrad NSS8 and digital Suzi gauges 

(new DF150 due end of September) 

Here's a few pics of the day's progress, pretty happy with the results :)  (Plastic wrap still on most panels, Steering wheel and Simrad)

- still got to fit the radios, stereo, trim tab switch and switch panel.

BIG thanks to Rod for the loan of his Hole saws - quality tools make a big difference !

looks great mate, and alot easier than trying to glass it.

almost looks like factory additions! i like the egdes, gives it a softer/neater look

Thanks :)

Yes, I got them to put a 45 degree bevel on all the edges - just makes it look smoother, plus reduces the edges / corners that might have made them harder to clean :)

great job Dizzy, looks great!!!!

CCC