Any chance you would share the materials you are using and techniques for shaping and finally the adhesive you plan to use to hold it together. A friend used 1/4 plywood for his, but the use of what appears to be ABS plastic looks so much cleaner. Also where did you source the materials.
I have to make a console for my build as well and I would like to follow in your footsteps.
First off, I will give credit to
@Kjsmitty for the idea to use it. I am just utilizing it a little different.
This is what I used, in both 1/2" an 1/4" thickness.
Marine Board HDPE (High Density Polyethylene) Plastic Sheet 1/2" x 24" x 48” Black Color Textured: Amazon.com: Industrial & Scientific
www.amazon.com
First off, there is smooth and there is textured. I am using the textured because it closely mimics the black "camera case" finish of the gauge and glove compartment and just looks right. Later on down the line I might upholster it but current plan is to go as is. I have 1/4" windlace for the exposed edges.
It is heavier than you might imagine.
I used 1/2" for the base and for the uprights. This gives plenty of support and material to screw into.
I used 1/4" for the sides. This allowed me to conform it to the curves of the base which follows contour of the tunnel.
Most of the cutting was with a skillsaw and sabre saw. If adjustable speed, run on the slowest. I tried using a pneumatic body saw but it ran so fast the material would get hot and gum up around the blade.
I am borrowing a router table from my Dad to plane the edges and put a rolled edge on the phone and drink holders.
Sanding the edges is a PAIN! Used the coarsest grit available, it is slow going.
I have used both wax pencil and paint marker to to do my layout. Surprisingly, the paint marker is my preferred tool here. Wax doesn't want to let go but rag with acetone will remove the paint with few strokes.
Right now, it is held together entirely with screws. I will be replacing them, and adding to them with black auto trim screws. Some parts will receive screws and epoxy. I am doing some experimentation but so far a plastic epoxy I bought yesterday seems to the most robust.
I won't be using any adhesive for the final assembly because I will have to attach the sides to the base once I set it in place. I will know for sure once I have the carpet in place but right now, I am pretty confident that because of the E-brake, it won't set in place as an assembly. I have an old doubled up floormat that I am using for mock up right now. I want to be able to get it back out if need be. The front panel will definitely be removable because the stereo guts, Dakota and cruise controllers will be behind there and in case I need to replace switches.
Incidentally, I was thinking of cutting up a leather jacket for the armrest and shifter/ebrake boots. Then I got to thinking about ordering in the same red leather as the seats. For the vinyl that looks like the leather, I was quoted $45 for a yard of it. That jacket might get the knife yet!