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Okay I'm back. Rogerspeed had me rattled so I just retrieved the dash from the test area ( driveway under a 58 MGA windshield) and today's test results are in: Keep in mind 99.9999 % of the dashes out there are not as bad as mine. The only issue I can see of out gassing is a 1/32 to 1/64 wide crack about 3/4 of an inch long at the back wear the dash ends near the window. Once installed it will never be seen!
That concludes DAY THREE of sun test.
The foam was home depot "great stuff" and yes I wanted it to expanded because I wanted it to fill cracks and slightly over flow the dash as to cap off the crack and so I can sand it level. Keep in mind the the body filler is not to be used as a leveling element but a "pours of the foam filler". That is why I think it has worked so far.
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