Building a Console: What Materials to use?

[jackfrost]

hmmm... i've found fiberglass is pretty easy to work with. just wear gloves, and know you'll be doing a LOT of sanding.

I think it depends on what sort of design you want. if it'll be mostly square, then go with steel or MDF. if you want it to be rounded or curvy, then make a frame out of MDF and stretch fleece over that you can fiberglass, similar to the way sub boxes are made. that's the approach I'll likely be taking.



also, take a walk through the junkyard, and see what's available. you might be able to get one that's close to what you want and modify it to work.

[venturabeachpup]

Here's a technique I've used to build some fiberglass parts that can be addapted to building your console. Build your frame with small wooden slats. Cover them with clay and shape the clay to the shape and dimensions that you want. Then the clay gets covered with a couple inches of plaster. Let the plaster dry hard and then remove the clay and wood.

You should end up with a plaster mold that can be lined on the inside with fiberglass resin and cheese cloth. Let the fiberglass harden and break off the plaster. Now you have a lightweight, in the rough, fiberglass console that you can work with.

It's a lot of work but the sky is the limit on shaping it and the part comes out pretty. (and lightweight)

[George]

The way to go is wood/wire frame then use Lycra or an old t-shirt or some kind of stretchy cloth.

The clothe goes over the frame to create curves and what not, then fiberglass over it.

Ive used this technique for making custom subwoofer boxes and it is very easy and very cool. The end product is very custom with curves and turns that you cannot duplicate with wood/metal. Plus its light and easy to sand/paint use body filler, etc, top with adhesive and leather/vinyl.