The first item on the list of things to do when you decide to build a custom center console is form an idea.

A possible end to the journey that you are about to begin, just remember that there will be points along the way where you will be forced to choose another path.

It never fails, there will be something that you forget to include in your original plan and you'll have to make a change that may or may not affect the finished product.

Put your idea down on paper, even a rough sketch will serve to keep the goal in mind.

As you form your idea take caution to plan in as many of the finish details as possible, there is no better time to decide just where to place a seam or transition between fabrics or surface textures, than at the beginning of the project.

The followins series of pictures covers the progress of a center console that I built for a 2001 Ford Excursion, the unit was needed to cover an assortment of processors and modules for the installed Alpine Multi-Media system.

I started the process by deciding where the components were to be mounted and what needed to be done to cover these items and blend cosmetically with the vehicle interior.

To build a console that fits your needs and is nice to look at, you're going to need some supplies. Take a little time to assemble the following articles.

• Cardboard scraps: for copying necessary contours.
• Pencils: Duh, for what else.
• Scissors or Utility Knife: for trimming cardboard and materials.
• Fiberglass fabric: Because I said so
• Resin: yup
• Catalyst: uh huh
• Bondo or other filler: you're going to make a mess
• Coarse Files and Sandpaper: for shaping and finishing
• 1/4" & 1/2" MDF:for skeletal construction
• Hot Glue Gun: for temporary positioning of skeletal components
• Grill Cloth or Old T-Shirt: for covering the skeletal frame
• Spray Contact Cement: to make things sticky
• Vinyl and Carpet: to cover your console
• Jigsaw
• Clamps
• Wood Glue
• Nailer or Stapler: preferrably a fine wire stapler, suitable for upholstery work
• Bondo Spreaders:for spreading Bondo
• Paint brushes: for application of resin
• and last but not least your plan

Try to imagine your console as it would be in the vehicle, then use the cardboard to copy the necessary contours in the vehicle's interior.

Remember that your goal is to blend the new addition into the interior as if it were meant to be there. Pay attention to the way that other parts of the vehicle join together, and the details that define their relation to one another.

If the contours of the dash are round, then your console should have the same type of corners and curves.

If the interior is clean and well defined with straight seams and sharp corners, then a console with round edges and curved surfaces will look out of place.

Dont wait until the project is near completion, test for fit as you add parts and before you make any permanent decisions of where components are to be placed. Some things seem right in the planning stages, but don't flow when it comes to physical placement or asthetic consideration.

As you test fit your frame, add components as you go. take time to make it fit properly, remember to allow small gaps for the covering material.

Always keep your plan handy, refer to it often and note any changes or problems that arise.

As you assemble the pieces of your puzzle, be sure to allow plenty of space for the components to be housed in your console, open areas beneath the surface will make it easier to hide bundles of wire and forgotten electronic modules.

Remember that your console needs to be functional while the vehicle is being driven, not only does it need to look cool when the doors are open, but the components housed within and any compartments used for storage should be accessible from the driver's seat while the vehicle is in motion without creating an unsafe condition.

Keep modules that require access for adjustment in position for easy operation. Allow plenty of access in front of the components so that the insertion of a video tape or CD doesn't turn into a wrestling match.

Use the Hot Glue Gun to hold the parts of your console in position while you assemble each of the pieces. This will allow you to move the parts if needed, after each test fit you can pull the pieces apart and reposition them where you want.

If you look at the skeletal frame edges, you'll notice that there is a small lip that has been added to the outer top edge. This is provided as a means of both attaching the vinyl and a point of transition for the seam to be formed between the vinyl and carpet covered surfaces.

This lip is also a point to which the preliminary layer of grill cloth or t-shirt material can be attached, before the subsequent layers of fiberglass are added.

You'll also notice that all of the edges that are to be covered with fiberglass have been rounded, this is done with the coarse file, and should be done wherever you plan to have vinyl covering your console.

Lay the grillcloth or t-shirt over your assembled skeleton, and pull it taught pay attention to any deep curves that your console might have.

Look for wrinkles that are forming in the fabric as you cover it, take notes of where they appear and which way the fabric has to be stretched to remove them.

This will come in handy later when you are covering the console with vinyl.

Add staples wherever you need to secure the fabric in position, you can remove them after the first layer of resin has set.

Use the paint brushes to apply a coat of resin to the covering material, try not to paint too much resin into areas that will be trimmed away later, this will make the next step easier to achieve.

Once the initial layer of resin has set, trim away any excess material before you begin adding layers of fiberglass.

Doing so will keep the shaping and finish sanding to a minimum, it will also make it easier to see what you are heading for.

Step nine: Plan for the party

After the fabric has been set and trimmed, move right on to the additional layers of fiberglass.

Add extra layers where you will need the extra support.

Keep in mind how many times you've leaned on your present console, and remember that this will be happening to this console as well.

There is nothing worse than a good looking, functional console that collapses when you least expect it.

After trimming away all of the excess fiberglass it is now time to smooth out any bumps or ridges that might have formed, as well as filling in any wicked dips that can cause frustration during the covering process.

Add thin layers of Bondo then file away the excess until you've achieved the surface that you desire. Follow the rough surfacing with additional thin coats of Bondo and finish sand until smooth.

If you have made it this far you should be feling pretty good about yourself right about now. But rest assured, this is where the men are separated from the boys.

The finish layer will either make or break your project, if you've paid attention to some details along the way you should not have any problems with this part. But if you've tried to skip any steps or take any shortcuts, it will definately show.

The vinyl should be treated the same as the initial layer of fabric that made up the first layer of the surface. If you made any notes about trouble spots (where creases and ridges formed) you should refer to them at this time.

Apply the spray contact cement to the console and the vinyl, alternate the direction of application to insure a good bond.

Start covering the console with the hardest contours first, follow that with the transitional parts, those that rest between complex curves and contours.

Pull the vinyl in a manner that reduces the amount of wrinkling, but not so much that the grain is diminished.

Use a heat gun to insure that the vinyl is pliable, and keep it handy throughout the covering process.

Prepare the carpet inserts, any carpet that is to be attached to the console should be first attached to a chip board or light cardboard substrate, this will make the installation easier and allow for a cleaner seam between carpet and vinyl.

As you get the vinyl into the desired position, firmly attach it to the console frame with staples, then trim away the excess vinyl.

Any openings in the console that need to have the vinyl extend through the opening should have the vinyl indented as you work on covering that area. The surface indention will amass some extra vinyl in the needed corners and allow you to get a clean appearance to your opening, no bare wood.

Just that, now that you are done with the actual fabrication the only thing left to do is install the unit in the vehicle.

If you've done a good job it should slide right in and everything should fit without need for any last minute modifications.

The installed product should fit without any gaps between the edges of the components and the opening.

In this case the console fit perfectly, without the need for any additional attachment devices, everything fit snugly and held each of the components in position without any unsightly screws or other visible fasteners.

When I grow up I want to be just like you...becaue you are the man...this is your world, I'm just paying rent

is that grill cloth that you have stretched over the console?

did you staple the vinyl underneath that lip that you made around the transition between vinyl and carpet?

quote:

---

Originally posted by Tim-E:
ok, how'd you get the glass so smooth, more importantly it seems as though you got every little air bubble out. HOW?!?!

Fiberglass rollers, use them to smooth the cloth out and remove any air bubbles that form.

Is that grill cloth that you have stretched over the console?

It's an old T-shirt, I normally use grill cloth, but I wanted to illustrate that any pliable cloth will work.

Did you staple the vinyl underneath that lip that you made around the transition between vinyl and carpet?

Yes, that is the main reason for having the ridge in the design, it allows the two fabrics of different thicknesses to be positioned close to one another without looking out of place.

You glue the carpet to cardboard and then glue the cardboard to the console? what is the reason for this, i've worked with carpet before and had no trouble, in fact when the guy at the upholstery shop saw it he said it looked VERY professional.

It allows me to prepare the carpet for installation after the rest of the console has been covered, what is not shown in the pictures is that the carpet panel is fully prepared and trimmed before the fiberglass has been layered. The cardboard is cut right after the edge treatment (ridge) is cut, just before it is attached to the rest of the skeletal frame.

---

This console was built in about six hours, during classes that I teach for installers.

quote:

---

Originally posted by OGB1:
How did you secure the center console to the car?

---

The console is wedged between the main dash panels and the factory center console.

quote:

---

Originally posted by kicker SPL!:
How Did you make the lip,In step 6?

If you take a look back at the picture from step two, you'll notice the cardboard templates for the side panels.

When I cut the side panels out of the MDF, I also cut an extra pair for use later when I decided exactly how much of an edge I wanted to have for the glass and vinyl to be attached to.

Then look to step three, you'll notice a line sketched on the right side of the console frame.

This is where I was making my final determinations as to just how the edge was going to look.

Now back to the pictures in step six, you can see the difference in what was planned and what was built.

When it came right down to it, I made a decision based on how it looked at the time I was beginning to attach the edge treatment, I just kept trimming and test fitting until I was satisfied that it would blend well with the vehicle interior.

What kind of mods in the steps would you make for a car console?
Say one that has a gear shift on the hump plus e-brake.

Definately a large opening to accommodate such components, then trimmed with contrasting materials such as brushed aluminum laminate, of maybe a carbon fiber trim panel.

Take design clues from the OEM manufacturers, they spend millions of dollars getting this stuff down right, you can use their designs as templates for this sort of fabrication.

When you take apart a vehicle, look at the way things come apart, and how they blend one surface to the next.

Attention to their techniques will help you decide to build complementary fixtures that blend nicely with the rest of the interior.

I was thinking of like one that had slots for like 5 cds that would be easy to grab.So you don't have to go to the folder.maybe a place with a lid.

For accessories like this, take a trip to your local dollar store, they usually have cheap desktop cd holders that you can glean parts off of for use in your planned project.

---