Looking to make a new dashboard - was thinking of making a cardboard template then tracing on to my aluminum but for the life of me I can't figure out an easy way to trace the contour of the window Any tips or ideas? I know I'm way over thinking this
Make sure your cardboard is thin enough. Tape it in place and then trace the windshield with a crayon. As the cardboard bends up into the windshield.
That's the rough. Cut out at the edge of the crayon line and slide it back in to check the fit. If you have a little gap someplace fold a piece of masking take over the edge enough to cover the edge of the gap and mark it with a pencil.
Keep checking until satisfied. Add masking tape to fill just trim to remove
I wouldn't try to nail it all in one shot.
Poster board can make a good template, including bends.
Do a rough in w/ the poster board with any bends included but leave a gap between the main template and windshield curve. Tape in place. Cut smaller width sections of poster board one piece at a time to fit the curvature of the windshield and once satisfied with the fit tape it to the main template. Cut and fit more small sections and tape as required till all done. If it takes half a dozen small sections taped to the main template so be it.
If the main template needs removed for any reason mark witness lines so it can be replaced to it's original position and tape in place.
Unsure of the OP's situation here, no current dash, roll cage etc., thas all I got. Pic would help.
I've made hundreds of templates, in my job and on my own projects. As mentioned above, don't try to get it in one shot. Make a base template for the easy part, then do little ones for corners, etc. The pix shown is one of the easy ones I have done. The tough ones are on an exterior surface - trying to get an accurate rendition of subtle surface transitions.
Contour gauge
Make a flat line reference a couple inches back, use this to trace the contour and then transfer to your original piece using the reference line.
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