I’ve been working on the sides of the center console. They probably don’t look like much, but they turned out to be a bit of a pain to engineer. I tried several different materials in several different shapes and thicknesses. What I ultimately ended up with was welding studs to the central tunnel forward of the center console, with an aluminum frame bolted to that. The aluminum is channeled in cross-section so that the material that forms the console side can sit down in it. That material is more of the .031″ plastic that I made the headlight surrounds out of. The channel is way bigger than that, I think it’s .250″ or so. So I slipped some rubber U-shape over it, so a tight fit was provided for both the sheet and the channel.
Finally, I saw on an episode of Project Binky that they were using something called Flexform carpet, which is good for going around contours. I bought a couple yards off eBay, but when it arrived, I didn’t really see how it was going to work very well. It is advertised as “stretchable and moldable”, but trying to stretch it did not seem to be working well. I finally figured out that it does not really stretch where it needs to be larger, but rather it scrunches up where it needs to be smaller. I got out the spray glue and went to work on the passenger side, molding the carpet around the .031″ sheet, which had some fiberglass reinforcing the contours where it was not flat. Here is where that ended up.
Note the correct map lamp, thanks to my friend Nial in the UK, who has his own 037 project going on.
Then a test fit in position. Passenger side.
I’m pretty well pleased with how those came out. I’m currently working on the center tunnel cover, rearward of the center console – the part that covers the e-brake and shifter. Once that is complete, I’m going to create the fascia for the kick panel areas. And when that is complete, I am going to declare construction complete, and blow the whole thing apart for final finishing.