Brand new '07 6MT September 30 2007
First step was to mock up the concept with foam core. The walls are 2.5" tall in the mockup; eventually changed to 3.5" for the actual prototype.
After a number of hours with the compound saw, table belt sander, and portable belt sander, the rough form takes shape. It was a challenge to get the pieces all perfectly cut with right angles when required. Some pieces are angled: The parking brake stub-wall, the front wall, and the rear wall. The three side-walls, and the interior wall, are vertical.
Because I knew the stock console has a crown to it, I set the flat-bottomed skeleton assembly of walls (everything but the top panel above) on 1/2" blocks along the sides of the console, and then transferred the contour of the crowns across the center, onto the internal ribs and exterior walls. Then tuned them in with the two belt sanders. I had to do this before gluing on the top (shown already in place here), but I didn't take any pictures of that.
You can see how the interior walls are notched and curved to fit the top of the original console.
Here's how the compartment looked at this point.
These cupholders came off Ebay, for $1.98 for the pair, plus $6.50 shipping. Also you can see my first prototype of the cushion. Decided the curve was stupid, and would make it harder to cover. Sawed the front of the cushion off, making it a rectangle. Sawed MDF and foam in the same cut.
I had to test the 32-oz Big Gulp for tipover behavior. Passed. Cupholders are 3.375" deep.
Gluing on the vinyl is pretty tough to do. Contact cement is not easy to work with. Add the fine cutting of vinyl at the corners (or near the corners) and it's about all I can handle. Took no pics of this. It was hard enough already.
Test fit. The contours are a go. It's solid.
Here's how the compartment looks now. But I don't know if I'm going to keep it this way. I'm thinking of adding a floor with a pumpkin-lid type opening in the floor to permit access to the lower compartment. That's the tip of a flat-blade screwdriver inside.
After getting the cover custom sewn, I routed out the appropriate positions along the hinge, and at all 4 corners, so that the double-layered vinyl at the seams would not lift the cushion assembly away from the main console top. Then I stapled vinyl and final-screwed the piano hinge (pilot holes were added before any vinyl was applied to either piece). The going gets stressful at this point because nothing has gone seriously wrong yet. Had to try pretty hard to keep things perfect because I had never tried various operations like routing for clearance and stapling...I guessed on the pre-stress to the vinyl as I stapled. Turned out to be about right.
And finally, the finished product.
