Custom center console questions/opinions

[YelloTx73]

After looking around at a few others people consoles in the broncos, I have decided to make my own. I plan on running it from the dash to the back of bronco to reach the back seat passengers as well. My first question, is what kind of material is best. I was wanting to do fiberglass, as a good buddy of mine used to build boats and is more than willing to help. My other choices were starboard (marine grade wood type stuff) or metal. Would prefer to stay away from the metal if at all possible. This bronco will see offroad use and am wondering if fiberglass will be able to hold up. I already have a design sketched out and just wanted some opinions on what might be the best idea. I will be mounting a floor shifter for my auto and running my twin sticks through the console, so that I have all my controls available with one hand. TIA guys! If this doesnt make since, its because the beer might be doing some of the talking, later I can clarify some stuff if anyone has any ideas.

 

[ken75ranger]

Fiberglass will hold up real well for you. Go to craft store and pick up the size foam blocks you need to make your console. Carve it to the shape you want. Put aleast 3 layers of 'glass roving mat on the foam template. Rip/carve out the foam as needed. You can make the inside and outside any shape you want easily with the foam. Once that is done put on aleast one layer of woven mat inside and out to smooth it out. If you get started and need some more tips let me know. Your boat builer friend can help you out alot with this.

 

[70bucks]

Fiberglass is what I'm planning to use on mine. I have been in the planning stages for a while trying to decide how to create a mold. Never thought of using styrafoam as YelloTx73 suggested. Do you need to apply mold release to the styrafoam, or will it come out clean when finished. I assume you don't or glassing the inside wouldn't work too well.
I think fiberglass will hold up if it will the take the abuse as a fender. Best part is, the shape is only limited by your imagination. One of the guys at work subscribes to a car stereo magazine (don't know the name), and they have lots of tech articles on the stuff. A lot of the import costom guys are using it to create interiors. Good luck. Don't forget to post pics.
Joe

 

[YelloTx73]

Thanks guys. I figured that fiberglass would be the way to go. I'll try and post some of my sketches later so ya'll can see what I'm talking about. I've been thinking about this console design for a while, so hopefully it will look at least like something I wanted.

 

[Fathom]

Do you need to apply mold release to the styrafoam, or will it come out clean when finished. I assume you don't or glassing the inside wouldn't work too well.
Joe

You leave the foam in where there is a void and cut out/channel where you run wires and have your shifters come through.

Hope this is clearer then mud ;D

Fathom

 

[YelloTx73]

Whats the best way to attach the fiberglass console to the body of the truck? Anyone done this or have any ideas?

 

[rob wilson]

I'm mid-project (a never ending state with my Bronco) of designing and installing a custom console also. Chose to go with steel (1/2" box) mostly for strength reasons but also because I'm not a FG guy. Since I'm also doing a custom dash and wiring harness at the same time, made several changes to stock.

1. Moved all switches from the dash to the top of the console. With the 4 points on, I can't reach the dash so I moved the switches so they will all be under my right hand (when not shifting)

2. Moved the fuse box to under the console. The top half is hinged at the rear. With it open, I have full access to the fuse box and all wiring so maintenance and updates will be much easier than working under the dash.

3. The console will also have the remote for a marine stereo that is mounted in the glove box on it. Again, since I can't reach the dash, this provides access while keeping the hardware out of harms way (and the eyes of potential thieves since I don't run with doors or a roof.)

All the switches (Carling) are waterproof rockers. There are lighted indicator lights with associated text mounted outboard of each rocker that indicate status.

Still a long way to go but I'm thinking it will work well.

Photos below show the frame (will be covered with sheet metal) with a printed version of the switch panel that will be installed on top. Second photo shows the console opened up for access to the fuse box.

 

[ken75ranger]

Whats the best way to attach the fiberglass console to the body of the truck? Anyone done this or have any ideas?

It kind of depends on your design. I'd go through the bottom. Just use some fender washers and make sure the glass is touching what you screw it to. If you draw the glass down while tighening it it will eventually crack.

 

[ken75ranger]

Fiberglass is what I'm planning to use on mine. I have been in the planning stages for a while trying to decide how to create a mold. Never thought of using styrafoam as YelloTx73 suggested. Do you need to apply mold release to the styrafoam, or will it come out clean when finished. I assume you don't or glassing the inside wouldn't work too well.
Joe

70, Most of the ones I have seen The foam is left it for extra support. They carve out what the want open and leave the rest. Then add a cuple of layers to the inside to finish it. The green stuff they sell at the craft store is a lot easier to carve out than genuine styrofoam. It's the kind used to make floral arrangements.

 

[KST1]

It's been my experience that normal styrofoam will simply melt when the resin is applied to it. I molded a hood scoop for my rig once and I had to wrap the foam with tin foil before applying the resin. The scoop was eventually destroyed before making it on my rig...

Does the green stuff from the craft store hold up? I've also heard that there is a foam insulation type that can be bought in sheets (4x8) that will hold up. I know it's not the pink stuff as I've tried it also. Melts instantly. Does anyone know if the blue stuff will stand up to the resin?

For those who are timid, give the glass a try, it's actually pretty fun to work with. I don't care for the sanding though.

Any web links to any of this kinda stuff?

-D

 

[ken75ranger]

It's been my experience that normal styrofoam will simply melt when the resin is applied to it. I molded a hood scoop for my rig once and I had to wrap the foam with tin foil before applying the resin. The scoop was eventually destroyed before making it on my rig...

Does the green stuff from the craft store hold up? I've also heard that there is a foam insulation type that can be bought in sheets (4x8) that will hold up. I know it's not the pink stuff as I've tried it also. Melts instantly. Does anyone know if the blue stuff will stand up to the resin?


Any web links to any of this kinda stuff?

-D

I'll have to check with a guy at work.

 

[YelloTx73]

Hey Ken, do think that the green style styrofoam, if I were to leave it in, I dont want to, anyways, what heat does that stuff burn at? My tranny tunnel gets awful warn, and I dont want to catch anything on fire inside of the console, since thats were alot of wiring will be as well. I'm probably just over-reacting though

 

[ken75ranger]

Hey Ken, do think that the green style styrofoam, if I were to leave it in, I dont want to, anyways, what heat does that stuff burn at? My tranny tunnel gets awful warn, and I dont want to catch anything on fire inside of the console, since thats were alot of wiring will be as well. I'm probably just over-reacting though

My guess, at least 400 degrees to melt. Open fire, well the 'glass will burn at the same time so I wouldn't worry. %)

 

[YelloTx73]

My guess, at least 400 degrees to melt. Open fire, well the 'glass will burn at the same time so I wouldn't worry. %)

Well if I have an open fire, I dont care what burns, as long as I'm alright and can get it out quick. As for the mounting, I figured that I'm going to run a strip of 1'4" - 1/2" rubber along the bottom of it to make a nice tight seal with the floor and then screw it down at each corner, not too sure if I should screw the middle in or not.