Making a center console

['68 Coronet R/T]

Not sure where to post this but I need some advice on design and construction of a center console for a 55 Chevy truck with a bench seat. I want it to encase the Old Air center A/C vents that mount under the dash, hold the ignition key, the air bag gauges, the air bag controller and maybe two cup holders. Needs to allow the bench seat some movement as well.
I know to make templates of cardboard but was wondering what are then best materials to use. I see some use sheet metal, others wood and some PVC sheeting. My concerns are durability and strength (especially with the ignition switch) and how to properly fasten it to the vehicle. This will be my first attempt at this and I would appreciate any tips and guidance you have to offer.

 

[Prplpny68]

I have made a handful of consoles similar to what you describe. My best friend back home does custom upholstery for a living so I can always "phone a friend" if I need to. What I have found best is to use MDF for the box and general shape structure. I use nails and wood glue and it holds well. If I'm going to need some nice curves or rounded areas, I wrap the whole thing in polyester material and staple it down. You can pull/tuck/stretch the polyester to get some cool shapes. Once you're happy with that, soak the whole thing down with some fiberglass resin. And I mean SOAK it. If it's not thoroughly saturated it won't have much strength. After it dries I go over it quickly with 36 grit on a zizz wheel just to scuff and knock off the high spots, and apply another coat of resin. After that I do all the smoothing with body filler. From there you can prime and paint or wrap in vinyl.

Look up custom sub boxes on google or youtube and you get some pretty good ideas. It all works about the same. Best of luck.

 

[Prplpny68]

Here is a rear view of the console in my F-250. I added a hidden compartment, cup holders, and LED lights on a separate switch. I had to curve the back of it so the rear seat would clear when it's folding down.



And I made custom arm rests for my mustang the same way. Only instead of using MDF I used 3/8" plywood.

 

[crashtech]

It really depends on what look you are going for. If you want a flowing/complex look you might go 'glass, if the shape is relatively simple, then a round bar stock frame with sheet metal worked over it would be fine. Then again I made a clear coated solid oak console for my old Buick that was actually pretty nice, even put in a couple beverage holders.

 

['68 Coronet R/T]

Thanks for the replies and the photos.
I guess I'll have to work up my cardboard template and see which way to go with materials. I plan to cover it with vinyl to match interior colors. Maybe use some type of plastic sheeting for the gauges and ignition key mounting surface.