DIY center console (1 Viewer)

[jblueridge]

I removed the rear heater unit from my BJ74 months ago.
Recently I have been using 2d and 3d CAD software to develop a new center console.
This thing will be in between the two front seats.
I will add some plastic trays or inserts so as the console fills with dirt and dog hair, I can remove and empty the trays.
I plan to use 5mm "aircraft" plywood for the real thing.

I used the school's laser engraver to cut out a cardboard scale model.

Eventually I made a full size version with the laser cutting foam board. The laser can't cut the plywood I will use but it can trace on it.

I used the 3d printer to make a trial insert that will go in the front. Dimensions are off a little. I will have to sand or re-print.

 

[clintnz]

Cool! I will be following with interest. I could make a lot better use of that area in my SWB - when touring with a full load of camping, hiking & MTB gear every last inch of space counts!

Cheers
Clint

 

[jblueridge]

I was out measuring today in the rain.
I think my very small but useful dc-ac inverter will fit under that main box. It can charge camera batteries or provide another usb power source.
I may try to build a small lock box there with a door facing rearward then mount the console box on top.

I'll try to do everything in CAD so files can be shared, modded, etc.

 

[jblueridge]

I bought 5mm aircraft grade plywood from Wicks.
wicks

I had to cut it to various sizes to fit them into our school's laser engraver.
Pasts smaller than 12in x 24in.
Laser traced each part as designed in CAD.

Lots of hand jigsaw work. Finished notches with a variety of wood files.

I used 30 min epoxy glue and every clamp I could find to assemble. Plastic to prevent gluing clamp to wood.

Using the plastic prevented me from wiping off excess glue. I now have epoxy is some places where it will be hard to remove.

 

[JPD]

Really nice work!

You should think about selling the templates! I would get one for sure.

 

[jblueridge]

I can send the CAD files to you if you want.

 

[JPD]

I can send the CAD files to you if you want.

Would be very appeciated!

 

[jblueridge]

I got the most complex insert made. It fits now. Eventually I will re-print with black ABS plastic.

 

[jblueridge]

Had some time to mess around with the base for the console. It is a stainless box that bolts to the welded nut floor tabs the rear heater used. It jacks the rear of the wood console up to match the level of its front.
I had the stainless left over from some other project. I used 3d CAD software to make a pattern. The holes are for air flow if I decide to put a small inverter or stereo amp in there.
The shop that cut and bent the sheet for me had a hard time doing it. Deep bends and the sheet is 14 or 16 gauge: pretty thick.
My pinch/spot welder was able to sort of tack the seams but I brazed them to make sure. It warped some but only the top and bottom need to be fairly flat.

 

[ivanhoe]

Nice work! Looking for a cup holder along with storage/armrest for my BJ75 which has little room to work with. Those CAD printers are very useful