quote Originally posted by 87GT2M6: much it would be to reproduce for those who want to buy one...

Hey 87,

I'm actually going to rebuild an all new console using the same steps Archie takes to building his fiberglass projects. That way I can get everything to measure evenly, clean lines, straight edges and there's no guessing. Right now, I'm figuring 3 pieces to start - the lid, glove box and main console. The armrest will come later. Once I have those masters made, I'll look into what it would cost to use that as a plug to create more.

Cost? 1 billion dollars! muhuhuhahahahaha... Actually... I have no idea... maybe 200 - 300 dollars. But that also depends on sanding, prepping, etc... and the cost of the molds.

I hope this helps?

[This message has been edited by Sofa King (edited 12-18-2009).]

[This message has been edited by Sofa King (edited 12-19-2009).]

As Promised!

Just laying glass to the front and back of the glove box.



Securing the front plate for the cup holder


I'll trim this up, spread some filler and sand it smooth


OK so... not that many pics... but better than nothing. It is cold and the resin is taking a little longer to dry... UGH

[This message has been edited by Sofa King (edited 12-19-2009).]

Hey P,

I used all 3 - foam, resin and glass. I quickly realized that the resin, while strong, is only a very thin layer and will not keep the foam core from snapping - it is after all just paper and foam. It needed a little bit of glass to give it the strength required.

Now - UPDATES!!!!

I went ahead and began to sand the inside of the glove box and added lot's of body filler. Since this is going to be laid in felt - it doesn't have to be perfect!


Another - catching some rays


I also filled the 12v outlet hole




Believe it or not... this little area has required the most sanding I've ever done. Although it's going to be covered I still need to knock down the high areas - total pain!


And more sanding


AHHH... I shall call him... MiniResin


Slight set back. While sanding the armrest, the front plate that I attached popped off. I'm now adding more resin - it has been really cold and I'm wondering if that's having anything to do with it?

Now... on to the good stuff... Remember all that foam core I purchased? Check it out! Armed only with a ruler, X-Acto Knife and VERY little common sense... I have begun work on Console Part II. The first thing I did was trace an outline on the foam core using the original console. This console is slightly bigger than my first console but should still fit snug


This was the fastest console I've ever built! Other than taping together - it took about 15 minutes




Inside shot - you can see how perfectly straight the lines are. This makes it easy to create the new glove box


Marking the new glove box lid - the nice thing about foam core is that it's cheap and if you make mistake - it cost 50 cents - not 35 dollars




Following the same lines as the original console I cut the edges to ensure it fits in the car


Another


I then tapes the edges


I rounded out the back part of the console




Here it is in the car - notice I added more space in what will become the glove box.


Front - FIT PERFECTLY!


One more - this new console will also be used to create more consoles should I decide to go "global" LOL


I spent about 1/2 hour to 45 minutes total on this new console. Why? I'm not ending at the console, like Katatak, I'm going to continue moving forward all the way through the radio / ac housing to the dash - I might even make a new dash - not sure yet. BUT! The foam core works wonders and allows me to see exactly what I want to do and what direction I want to head. I can also paint the foam core to get a better idea of color schemes, textures, etc... Can I use just the foam core to create a new dash? Yes and no. I have two directions:

1) Once I get everything in place and all the measurements made I take apart the console, create fiberglass panels and transfer those measurements to the fiberglass - that's a lot of glass work and a lot of fabricating but there's very little guess work.

or

2) With the foam core in place and using more masking tape than I know what to do with... I glass both sides of the console similar to what I'm doing to the glove box on the original console. I don't have to be as forgiving on the inside but I would need to work smart on the outside to ensure straight edges blah blah blah...

From here... the next steps for the new "foam core" console are to cut the lid and create a perfect glove box along with a new style armrest and mini glove box. This will also allow me to begin to design a new shifter plate and radio a/c housing.

Not to worry - I'm still moving forward with the original console build. Once the glove box is sanded smooth I will begin to put the final pieces together for the armrest (to include the mini glove box), lay the felt lining inside the glove box and lid and get to paint.

P (and everybody else of course),

Go back to Hobby Lobby and get a bunch of foam core! I promise this will help with any idea or direction you might have. And yes, you can cut curves - not compound courves, but you can do simple curves. I'll post a pic in a few. (JUST SAW YOUR THREAD! YOU GOT THE FOAM CORE! How funny is that! - Great minds!!!)

[This message has been edited by Sofa King (edited 12-20-2009).]