Custom console-materials? Plastics?

[switchblade327]

I am looking into building a center console for my Chevelle and have been scouring forums and the internet for weeks.

It seems the most common process is building a mold out of foam, mdf or luan then using fiberglass or resin to build the actual console. I've seen a few just out of mdf + upholstery and of course, some metal ones too (this would be my preference if I had the skills & tools).

What I haven't seen many of are plastic ones, though this is one good example:
http://www.snowdigger.com/the_garage/garage_projects/custom_console/console.html

Is there a particular reason we don't see more center consoles made of ABS or PVC plastic? I wonder if it's just the materials aren't as readily available or haven't been used in traditional hot rodding? My mechanic brought up interior heat as a potential concern (we are in Southern California) and it's my biggest concern as well but ABS plastic is rated to 145-155 degrees. I discussed the application with a technician at Tap Plastics in the bay area and they said ABS should be fine and plenty of factory interiors use ABS all over the place.

I was thinking of going down to plastic route, reinforcing with a few aluminum cross beams for strength.

Does anyone out there have experience with plastics for interior components? Is there some big concern with the material that I'm missing?

[cluxford]

see no reason for heat to be an issue. Look at every modern car, all they are made out of is plastic

[astroracer]

I am doing a small scale "console" for my '56 wagon. Actually just adding cupholders to the B&M shifter console. Using some 3" dia. PVC connectors I got at Lowe's for .95 cents each and some 1/8th inch ABS sheet. I used manilla file folders to make templates and cut the ABS on the scroll saw. Using the heat gun side of my soldering station to heat and bend the ABS. Haven't finished them because my back is out... I can post some pics if you want to see a partial process.
Mark

[switchblade327]

I am doing a small scale "console" for my '56 wagon. Actually just adding cupholders to the B&M shifter console. Using some 3" dia. PVC connectors I got at Lowe's for .95 cents each and some 1/8th inch ABS sheet. I used manilla file folders to make templates and cut the ABS on the scroll saw. Using the heat gun side of my soldering station to heat and bend the ABS. Haven't finished them because my back is out... I can post some pics if you want to see a partial process.
Mark

Sure, a couple of pics might be helpful. Thanks!

Part of what impressed me after watching some instructional videos is how easy it seems plastic is to shape. The sheets can be cut like wood but easily bent with a heat gun and still glued and/or screwed together. Especially if the console is going to be upholstered, it seems like it might be a more straightforward process than fiberglass, if the console isn't going to be too curvy (also, I live in an apartment and fiberglass is messy). I've already made a cardboard mockup and ordered sample plastics so I'm fairly confident I can build it, as long as it doesn't melt!

[astroracer]

Here are a few pics of my trial piece. I used this just to test the bend properties of the ABS. I made a cardboard template from a manila folder and bent the plastic with a small hot air gun. It bends real easy with a moderate amount of heat. Using the gun on the inside, the plastic does get a bit bubbly but it only goes so far before it is ready to bend.
https://static1.pt-content.com/images/pt/2014/07/photovi-1.jpg
With the PVC "cup holder" set in place.
https://static1.pt-content.com/images/pt/2014/07/photo3vi-1.jpg
I'll cut a notch in the PVC piece for a mug handle and paint it satin black with Fusion before attaching the assembly to the shifter cover.
Mark

[switchblade327]

Here are a few pics of my trial piece. I used this just to test the bend properties of the ABS. I made a cardboard template from a manila folder and bent the plastic with a small hot air gun. It bends real easy with a moderate amount of heat. Using the gun on the inside, the plastic does get a bit bubbly but it only goes so far before it is ready to bend.

With the PVC "cup holder" set in place.

I'll cut a notch in the PVC piece for a mug handle and paint it satin black with Fusion before attaching the assembly to the shifter cover.
Mark

Thanks for sharing these and for the tips, especially about heating the inside. My Chevelle used to have the same Megashifter with a 700r4 :)

[scott_fx]

Here are a few pics of my trial piece. I used this just to test the bend properties of the ABS. I made a cardboard template from a manila folder and bent the plastic with a small hot air gun. It bends real easy with a moderate amount of heat. Using the gun on the inside, the plastic does get a bit bubbly but it only goes so far before it is ready to bend.
https://static1.pt-content.com/images/pt/2014/07/photovi-1.jpg
With the PVC "cup holder" set in place.
https://static1.pt-content.com/images/pt/2014/07/photo3vi-1.jpg
I'll cut a notch in the PVC piece for a mug handle and paint it satin black with Fusion before attaching the assembly to the shifter cover.
Mark
i did a lot of abs modding on my corvette a few years back. you can use abs cement from the plumber supply section to 'weld' the pieces togeter or get a bunch of scraps and melt it down with some M.E.K. from the paint dept at your hardware store. you can make a thicker sludge with this stuff.

you can also make a plastic bender from a heating element and tow piece of 'L' angle aluminum pieces. this will concentrate the heat in a straight line.

also, keep an eye out for other abs things you can use to get complicated shapes. you can use pieces from tool boxes, abs pipe reducers (i use this to get a nice beveled ring), etc...

[switchblade327]

Good info! So why isn't plastic more commonly used? it seems easier to work with than fiberglass for some shapes.

Are there practical considerations I'm overlooking or just that people don't want too much plastic in their interior for cosmetic/purist reasons?

[MCMLXIX]

kydex is a plastic that can also be heat formed to complex curves. Its used a lot for firearm pistol holsters... found on ebay and comes in colors.
starboard is a relacement for MDF. Its used in marine applications where wood could absorb water and rot. its treated like wood, cna be glued, screwed and you can use a router for the edges. comes in multilple thicknesses.. not "bendable" because I think its only avaialble like plywood/MDF thicknesses ... also know as HDPE or High-density polyethylene

[switchblade327]

Thanks for that info, Rich. I'd never heard of Kydex! It looks like great stuff though a bit expensive for an entire console. It might be good for some of the detail work though.

I am a little more familiar with starboard. Seem like it might be an option for trunk panels and such, though it's a bit more expensive than MDF. I wonder about it's acoustic properties, like if speakers could be mounted in it.

[MCMLXIX]

come on ... nothing in this hobby is "cheap" ... LOL

a quick search says the acoustic properties are not ideal for a subwoofer box...

[switchblade327]

come on ... nothing in this hobby is "cheap" ... LOL


Ha!

[raustinss]

I believe it's dragon plate which sells all kinds of carbon fiber tubing and "connectors" as well as plate, the creativity level could soar and carbon fiber is just soooo cool,light,strong and sexy lol

[switchblade327]

I believe it's dragon plate which sells all kinds of carbon fiber tubing and "connectors" as well as plate, the creativity level could soar and carbon fiber is just soooo cool,light,strong and sexy lol

I just checked out http://dragonplate.com.

I know nothing in this hobby is cheap but some things are holy $#!t expensive :P A 12 x 24 sheet of 1/8" carbon fiber from them is a bit over $100. Same size sheet of of 3/8" ABS is $16. I need at 4-6 sheets that size. It would be great for a spare-no-expenses build though!

[astroracer]

This is a good place for ABS sheet.
https://www.onlinemetals.com/merchant.cfm?pid=21768&step=4&showunits=inches&id=1580&top_cat=181
Full sheets (4 x 8) are available here. 1/8th inch is $74 plus shipping.
http://www.usplastic.com/catalog/item.aspx?itemid=23013&catid=715

[switchblade327]

This is a good place for ABS sheet.
https://www.onlinemetals.com/merchant.cfm?pid=21768&step=4&showunits=inches&id=1580&top_cat=181
Full sheets (4 x 8) are available here. 1/8th inch is $74 plus shipping.
http://www.usplastic.com/catalog/item.aspx?itemid=23013&catid=715

Thanks for the links, Mark. I've ordered some aluminum from onlinemetals.com that I hope to use for reinforcement. I love that they'll custom-cut lengths of metal.

The plastic I am going to order from http://www.tapplastics.com. Their price is about the same for 24x24" ABS as onlinemetals but their site allows you to easily order custom-size cuts, which will save me some hassle on the long, straight cuts (I only have a jig saw) and some shipping. Also, I called them to ask about the heat question and some other, general questions about materials (it's how I came to settle on ABS as the material.) I was able to get someone helpful and knowledgeable on the phone within minutes, which is a rare thing these days.

The 1/8" sample seems pretty sturdy but I'm going to go with 3/16" for a little extra strength. Ordering today!

[scott_fx]

mcmaster-carr is also a good resource for plastic, though i think i've gotten the best deals on ebay (for abs at least)