I found this old post and thought I would use it to add updates to.
Keep some continuity going, and all that.
So , for 17 years of owning this car its never had a usable glove box.
A PO had cut a big hole in the rear for whatever reason.
I utilised some CAD skills Cardboard Aided Design.
I found that layering up the corn flakes box by 5, I got roughly the correct
thickness to match the glove box material.
I sprayed the large flat surfaces with water , one at a time, and clamped them flat and allowed to dry.
This brought a lot of neatness back, but don't clamp too tight or impressions are left in the surface.
Where it had delaminated I pushed a paint brush between with watered down PVA and reclamped and left over night.
It took a little over a week as I was leaving each bit of work to dry over night.
356 by
karlhash, on Flickr
356 by
karlhash, on Flickr
I then made a repair section by layering up cardboard over a spray can, this gave me roughly the shape of the back curve.
The spray can also came in handy for clamping the rear back into straight lines.
356 by
karlhash, on Flickr
Once I had a good shape to fit the hole I delaminated the cornflakes box for thin pieces of card and layed these over the joins of the repair patch.
All glued in with more watered down PVA.
356 by
karlhash, on Flickr
356 by
karlhash, on Flickr
After I was happy with the shape and patches, I mixed up some acrylic paint to match the grey exterior and gave it a coat.
Then I scraped or shaved out the old flocking with a Stanley blade.
Using the acrylic paint as the gluing agent, I painted the inside and blew light grey flocking fibres into it wet, with a home made
flocking blaster. I had seen manufactured blasters for sale and thought lets make one instead of paying £20 for basically a cardboard tube.
If you want to do the same, I found that a toilet roll tube diameter fits nicely over a kitchen roll tube.
I did add some masking tape around the smaller tube to get a better/closer fit. For the ends a yoghurt pot or similar sized desert pot is close enough.
With 5 holes punched in one end you are now equipped with a pump action flocking gun.
356 by
karlhash, on Flickr
356 by
karlhash, on Flickr
The finish is acceptable but not perfect, but that suits the rest of the car I think.
Most importantly though, my partner Hazel can open the the glove box door without a view of her feet and can actually put stuff in it !
Karl
356 by
karlhash, on Flickr
356 by
karlhash, on Flickr
356 by
karlhash, on Flickr