Thanks for the comments guys.
So I've had a few questions about building the console. Here's a response that I put in another thread and thought I would add it here in case more people are wondering what I've done.
As for the building of the console, it's actually very simple and no high cost tools needed. The biggest thing about building a console like this is time. It will take alot longer than building one out of mdf, but the nice thing is it's a custom piece that fits exactly how you want it to. It's all trial and error. Measure, cut, tack, test fit, fix, text fit and carry on :devil:
One of the tools is a ring roller, or a roll bender. Mine is a Magnum brand which I picked up from KMS Tools, a tool store that has a few locations throughout the province. I think I paid about $75 for it on sale. Here's the one that I have, it's very similar to the Baileigh one, I just didn't have to pay for the Baileigh name. I'm sure mine isn't as good as the Baileigh one though.
What this tools does is allow you to roll round bar or flat stock. You can roll it to a complete circle or just make a piece curved. I used this tool to do the pieces that fit over the trans hump in these pics
This allowed me to build the console so it would fit nicely on the hump. I thought about just using large barrel or tank to help shape the round bar, but for anyone that's seen my build knows..I like to buy tools so I decided I'd rather have the tools. I plan on using round bar in a few more areas of my build.
The second tool I've used is this.
They just call it a universal metal bender and I think I paid $40 on a sale. You can change the dies and it allows you to make circles in the metal. I paid $10 extra to get a DVD that shows what the tool does. Looks like guys use these to make round bar art when there are lots of bends. I used mine to make the piece around the parking brake in this pic. I'm also going to use it to build some pieces to hold up the cup holders.
Those are the only two specialty tools that I've used for the console. The other tools I've used are: a hack saw, hammer, vice, measuring tape, welding magnets and of course a welder.
The round bar that I'm using is 1/4". I got all mine at Princess Auto....it's kind of like a tool junk store that has several stores throughout Canada. Not sure what store would be similar in the US. You can also get round bar at Home Depot and most places like that. You would also be able to get it at most steel supply stores, I just prefer to get mine as I need it. I usually pay $5.49 for a 5 foot piece. I think Home Depot charges $4.99 for a 3 foot piece.
When you start your console, measure the area that want it to fit into and start cutting. If you want to use a piece of cardboard to make a template, that might make it easier to get the design that you want. I just use the trial and error method and changed it as I went. Make sure that you allow for clearance of carpet, underlay and any sound deadner that you might use. When I started to do mine, I forgot to do this and had to cut it down to allow for it. Use the welding magnets to hold pieces in place and tack weld them. I eye balled all my bends and angles until they looked good. Now that I'm doing a lid for mine, I may have to make a few adjustments to make up for the "eye balling".
As for the 90 degree bends, I used a vice and a hammer. Mark where you want the bend to go and put it in the vice. You may want to try a couple practice bends to see where it bends in respect to where you mark it. I start by bending it by hand as the 1/4" stuff bends quite easily by and. The problem with bending a 90 degree by hand is that the bend ends up quite rounded. Once I have it done by hand, I use a heavy ball peen hammer while it's still in the vice and hammer it down to get a nice tight bend. These bends were done by hand and then with a hammer.
Alot of the 90 degree bends are welded. This piece of the console has quite a few bends and they were all welded into place. You can see how this piece has quite a few odd bends and angles on it. This is because I wanted to make it fit just right. I had to make alot of the bends and angles to fit around the Vintage Air unit that's shown in the second picture
Like I said in the beginning, the biggest factor in building a console like this is time. I don't even know how many hours I've spent building this one. It adds up though once you tack things into place, fit, weld, clean the welds and test fit again and make any changes that you need to. Once mine is done, I plan on wrapping it with 20 gauge sheet metal and then with leather. The main reason I chose round bar was it allowed me to make a real custom piece that fit exactly how I wanted it to. It was also alot easier to make changes as I could just cut out the area I don't want and weld in a new piece. Not as easy to make changes with mdf or wood and still keep it strong.
With the questions I've been getting lately and seeing other guys make consoles with round bar, it got me motivated to do some more on mine. Here's what I've gotten done over the past few days:
Brian Hobaugh SCCA National Tour June 2014
First Hemi 'Cuda Convertible Ever Built
Short clips: Goodguys Pleasanton autocross and pit videos
Linear Mode
