Making of a center console

[Aquaticbob]

Disclaimer: I write a lot, if that scares you, there are pictures. This is in progress, it will most likely take a few more days to complete as I do a lot during a day.

I had been planning on doing this for quite some time now, but after reading the other thread with center console questions I finally decided to get around to doing it. My car is a '98 BMW M3, and in my opinion came with the worst center console to ever come in a car. The cup holders don't fit anything, it's not incredibly appealing, doesn't really store anything, and to me looks kind of cheap in the car. The goals for my center console were to have 2 full size cup holders (fit cans at a bare minimum), a spot to put my phone so it doesn't fly everywhere, and have a little storage.

The custom console had to look OEM+, and be extremely functional so MDF was out of the question (not to mention I **** at wood working). My decided process is going to be: Cardboard mock up, green floral foam block design, fiberglass over the foam to create a hard model, test out design for a week, create a cast mold out of the fiberglass, make a hard plastic final version. This process might seem long and drawn out, but I think it'll work out the best for my intentions.

I went to the drawing board and came up with 3 different designs, finally settling on one of them because I thought it was going to be "easier" to make, and would still be up to my requirements.

I started with taking out the center console and arm rest, this was pretty straight forward, the arm rest had 2 bolts in obnoxious places...


After that I got to work mocking up the cardboard. This took me a couple hours to get it there, but I finally got a cardboard outline that I liked.


The reasons for starting with cardboard are:
1. It's extremely easy to work with, and you can make plenty of alterations on the fly
2. It's cheap
3. When I make the foam model by using the outlines of the cardboard, the foam will be slightly smaller than actual size so the fiberglass that goes over it will be correct.
4. It makes far less dust/mess

Anyway, feel free to comment on your thoughts, I plan to have some more updates either later tonight (depending on how productive I'm feeling), or tomorrow.

TL;DR I'm making a center console out of plastic, going through way too many steps to get there to get a one of a kind product

 

[Kaasdief]

I dig this kind of thread. Very interested to see your to see the progress and final result!

 

[Aquaticbob]

Started working with the foam tonight, got all the foam glued together, and started working away at the E-brake area. Need to do more trimming to the overall piece tomorrow. Thinking of ways to make the storage area flow a little better other than just being a tower there... Will need to get creative with the foam a bit more

 

[softailgarage]

Hmm, interesting approach. Think maybe I would have started with a solid block of foam, I dont know Either way, I'll be watching this thread.

 

[k1rodeoboater]

Hmm, interesting approach. Think maybe I would have started with a solid block of foam, I dont know Either way, I'll be watching this thread.

It all works the same, this kind of stuff is easier to find at craft stores nation wide. I've seen people make motorcycle tail sections with that foam using this method.

 

[Stooge]

Pretty cool start with the foam block idea, Interested to see the progress on this

 

[bhays]

I'm all eyes. Neat project.

 

[kazlx]

sub'd.

 

[Aquaticbob]

Hmm, interesting approach. Think maybe I would have started with a solid block of foam, I dont know Either way, I'll be watching this thread.

Reason for blocks over one big solid block was the amount of carving I would have to do. A. I'm no craftsman B. I generally **** at these kind of things so I'm trying to make it easier on my self and C. It's easy to get general shapes and sizes down this way even if I have to glue pieces together and let them set for an hour or so.

It all works the same, this kind of stuff is easier to find at craft stores nation wide. I've seen people make motorcycle tail sections with that foam using this method.

I read from a few places this foam was used for a lot of different modeling things. I went to my local michael's and they had this foam or another type that they should have called rock that looks like foam. The only downside is if you sneeze near it, prepare for lots of green foam dust everywhere. Considering wearing a face mask from now on.

Pretty cool start with the foam block idea, Interested to see the progress on this

Thanks! There should be some more progress today. Just gotta get the razer blade and start carving away at it

 

[Aquaticbob]

Started at carving out the cup holders and phone holder. I'm only going to full carve one holder out to test depth and everything. The fiberglass will be just a hole there and I will be buying black plastic marine cup holders.

One holder almost fully carved, started on the 2nd. Phone holder will be full cut and model for the fiberglass to lay into. Thinking about making the holder removable to be a bolt down access point to keep the console secured. I plan on it securing in the front middle and back.

 

[Stooge]

Reason for blocks over one big solid block was the amount of carving I would have to do. A. I'm no craftsman B. I generally **** at these kind of things so I'm trying to make it easier on my self ........The only downside is if you sneeze near it, prepare for lots of green foam dust everywhere. Considering wearing a face mask from now on.

That was part of my first thought, trying to get all the plains to be carved perfectly straight and how terrible/ **** i am with stuff like that.
my small experiences with that green foam have been that gets EVERYWHERE.

what are you planning for the tower piece? some kind of storage area with lid?
i cheaped out on my cupholders and just mickey moused some exhaust tubing adapters together.

 

[bad_idea]

I'm in for this project. I have interest to make parts like this.

 

[Aquaticbob]

That was part of my first thought, trying to get all the plains to be carved perfectly straight and how terrible/ **** i am with stuff like that.
my small experiences with that green foam have been that gets EVERYWHERE.

what are you planning for the tower piece? some kind of storage area with lid?

The green foam does just turn into dust pretty much, and is very light so it is EVERYWHERE like you said.

The tower is going to be a storage with armrest type lid. To get a little more flow up to the storage area from the base of the console I'm thinking of a little ramp up curve with a push release on a spring hinge to open up to my phone holder. That or a sliding roll door type design. We will have to see which way i decide to go. I just don't want it to be too boxy. I'm just working away here and there on the foam today so should have some more updates later today

Glad to see lots of interest! I'll be doing a summary of everything once I'm done with the process, that way if anyone is interested should be able to get the step by step

 

[Rated ///M]

Ever worked with fiberglass before? You're going to have about 3 gallons of bondo on that by the time your done with it to get everything smooth...

Why plastic? You could create a mold from your first perfect bondo creation and just gel-coat and fiberglass it. even if you do plastic or fiberglass I am hoping you are keeping all your surfaces the correct angles so your plug will release.

 

[racingtadpole]

Electric carving knife will make shaping the larger planes easier and more uniform.

 

[ddx77]

Not to take anything away from anyone else but this has to be the best "console build" thread I have ever seen. From another forum.

http://www.pro-touring.com/threads/88754-Custom-Console-Build

Good luck with your's, I haven't had the guts to start my own yet.

 

[Aquaticbob]

Ever worked with fiberglass before? You're going to have about 3 gallons of bondo on that by the time your done with it to get everything smooth...

Why plastic? You could create a mold from your first perfect bondo creation and just gel-coat and fiberglass it. even if you do plastic or fiberglass I am hoping you are keeping all your surfaces the correct angles so your plug will release.

I've worked with fiberglass on boat hull repairs before. The fiberglass most likely won't be extremely smooth, but it's not the final material, it's just there to be a hard version of a prototype. I'll sand it and everything, which will be a PITA, but whatever. There are plenty of other ways of doing it, I'm going with plastic, it just seems to be the best for me at the time being. This is all just an experiment anyway, I'm curious myself as to how it will turn out. The end goal is to have a better center console, and if this method doesn't do a good job of it, I'll try something else

Electric carving knife will make shaping the larger planes easier and more uniform.

I don't have an electric carving knife to use for this. I have been using a saw blade to get the longer edges carved down, then I go over with a razer blade

 

[Aquaticbob]

Changing up the foam idea. More updates to come after I've worked through it all

 

[ilovevocs]

You mention that the final product will be plastic. Can you elaborate on that a little further? Are you going to vacuum form the final piece? I don't know how you intent to create the mold but I would consider designing a bit more draft into the part for ease of removal. I don't think it would have a huge impact on its aesthetic.


Sent from my iPhone using Tapatalk

 

[Jpeezy]

look up videos on youtube for fleece and fiberglass resin.

 

[liquidh8]

Like the foam idea, the only problem I have ever had with custom consoles, is they almost never have the same finish as the dash and always look tacked on.

I will be following you build!

 

[Aquaticbob]

Been awhile on an update, been doing quite a bit and haven't been able to mess around with this much. I need my current center console out of the car to work on it, which I've needed my car too much recently to do.

The green foam seemed like a good idea but it was going to take forever to carve out. I've got some expanding foam right now to mess with but I'm moving away from foam now I think. After I get done with my calipers rebuild I'll be able to get back to the center console as my next free time project.