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-   -   TJ Overhead Console Build Thread (http://www.jeepforum.com/forum/f37/tj-overhead-console-build-thread-956806/)

FlyinPhil 01-25-2010 11:43 PM

TJ Overhead Console Build Thread
 
Due to my lack of funds and Tuffy's overhead console being $400+, i decided to build my own console to house my stereo, cb, maxitrip auto comp., and a switch panel. Now i realize there will be some dispute about using plywood for the main body of the console, but i am a very adequate woodworker, so i decided to stick with what i know ( I didn't win the Construction student of the year award for doing nuthin' ! ). So the main issues i have heard with using wood for something like this are moisture and vibration. I used rocker guard over the whole thing, so moisture is not really an issue. Plus i gusseted (lol is that even a word??) quite will, so i dont think vibes will be a problem.

The design:
Due to my inability to plan stuff in advance, i came up with the overall design and layout of the console during a random stroll through home depot with one of my buddies. the idea seemed fairly solid, so i picked up most of the needed materials at that point.

The Materials:
One sheet of plywood ( got it from the scrap section for 51 cents )
one 1"x1/8"x48" steel bar. ( had to get another one later, so two were needed )
one 8' piece of 1/8" c-channel aluminum....lots will be left over. just need 44.5" for the front crossmember that goes between the cage bars.
a plethora of 1/4"x3/4"and1/2" bolts, with corresponding nuts and rubber washers for each
about 6-8 larger bolts (cant recall the size at the moment)
one 3'x2' sheet of galvanized steel (doesnt have to galvanized, but it was shiney.. )
some small screws, 1/2" i believe
lots of primer and paint
few cans of rocker guard
waterproof/outdoor glue
and a few other things i've probably forgotten but will add later.

In total this cost me just less than $150 ( the paint accounts for a fair bit of it ) not including the switches, stereo, wiring, etc.

Tools:
hammer
Assortment of saws: band saw, scroll saw, jig saw, hack saw are all good to have
Screwdrivers
Drill
Drill bit set....everything from 3/16s to 1/2" (for both metal and wood)......drill press would've been nice
a few files
marking awl
center punch
sandpaper
vice
anvil was nice to smooth the edge of the freshly cut sheet metal
tin snips

and again, i've probably forgotten something that i can add later

now, time for pictures

getting started

http://i540.photobucket.com/albums/g...onsole1066.jpg

planning stuff out

http://i540.photobucket.com/albums/g...onsole1068.jpg

cutting one of the sides

http://i540.photobucket.com/albums/g...onsole1070.jpg

the two identical sides next to each other

http://i540.photobucket.com/albums/g...onsole1071.jpg

The maxitrip

http://i540.photobucket.com/albums/g...onsole1072.jpg

a quick mock up of the stereo and computer

http://i540.photobucket.com/albums/g...onsole1074.jpg

Glueing.....the more clamps the better

http://i540.photobucket.com/albums/g...onsole1075.jpg

Deciding what to do for the switch panel

http://i540.photobucket.com/albums/g...onsole1076.jpg

I drilled 4 holes, one at each corner of where the switch panel housing had to be cut out.

http://i540.photobucket.com/albums/g...onsole1078.jpg

Mock up of the switch panel (though there will be 8 switches when it is done...one for the coffee maker, passenger ejection, oil slick....etc )

http://i540.photobucket.com/albums/g...onsole1080.jpg

cont....

FlyinPhil 01-25-2010 11:44 PM

holes drilled and hardware added to the switch panel housing

http://i540.photobucket.com/albums/g...onsole1082.jpg

CB pics

http://i540.photobucket.com/albums/g...onsole1083.jpg

http://i540.photobucket.com/albums/g...onsole1084.jpg

http://i540.photobucket.com/albums/g...onsole1085.jpg

here is a better mock up

http://i540.photobucket.com/albums/g...onsole1089.jpg

hooray for sheet metal

http://i540.photobucket.com/albums/g...onsole1091.jpg

using a 2x4 cut to the same diameter as the roll cage, i bent the mounting brackets for the front crossmember

http://i540.photobucket.com/albums/g...onsole1092.jpg

http://i540.photobucket.com/albums/g...onsole1100.jpg

http://i540.photobucket.com/albums/g...onsole1101.jpg


http://i540.photobucket.com/albums/g...onsole1102.jpg

cont...

FlyinPhil 01-25-2010 11:44 PM

brackets bolted to the crossmember ( c channel aluminum )

http://i540.photobucket.com/albums/g...onsole1104.jpg

http://i540.photobucket.com/albums/g...onsole1106.jpg

now due to clearance for the bolts on the crossmember, i had to drill out the inner bracket and weld the nut right into the bracket and grind it down

http://i540.photobucket.com/albums/g...onsole1118.jpg

ribbed supports

http://i540.photobucket.com/albums/g...onsole1107.jpg

my cat helping me out making sure that the wires for my radio don't get tangled

http://i540.photobucket.com/albums/g...onsole1108.jpg

wiring mess....i fired the cat...

http://i540.photobucket.com/albums/g...onsole1109.jpg

clean stereo harness

http://i540.photobucket.com/albums/g...onsole1110.jpg

some of the metal stuff primed...the large sheet at the bottom is for the top of the console

http://i540.photobucket.com/albums/g...onsole1111.jpg

the console rocker guarded, more pics to follow soon!!!

http://i540.photobucket.com/albums/g...onsole1114.jpg

DC4W-93XJ 01-26-2010 10:22 AM

VERY nice.... i think i've been inspired...

i think an MDF model would be much cleaner.. nice work..
:tea:

DC4W-93XJ 01-26-2010 10:23 AM

any installed pics??

MO2500 01-26-2010 10:43 AM

that looks really nice :thumbsup: installed pics please :D

5.7YJ 01-26-2010 10:56 AM

Looks great, please post some more pics!

FlyinPhil 01-26-2010 11:04 AM

hey guys, thanks for the input. as for MDF, it would definitely be cleaner and easier to work with, but it is also fairly heavy.....plus i got the plywood for a grand total of 51 cents, and only used half of it. when i do a new center console i will probably go with mdf.

its not quite finished, so installed pics yet, but i should have another update by saturday

Thanks again!

TennesseeTJ02 01-26-2010 11:05 AM

looks great!

FlyinPhil 01-26-2010 11:07 AM

Quote:

Originally Posted by TennesseeTJ02 (Post 8766778)
looks great!

Thanks! there will be more pics soon :thumbsup:

Unii 01-29-2010 10:57 PM

sweet i'd make one if i didnt have the tuffy already.

JWitt333 01-30-2010 09:49 AM

that looks really good. too bad for the cat though.

bdevr 01-30-2010 07:07 PM

Quote:

Originally Posted by DC4W-93XJ (Post 8766501)
VERY nice.... i think i've been inspired...

i think an MDF model would be much cleaner.. nice work..
:tea:

Keep in mind that MDF and moisture do not get along well. MDF act like a sponge and will fall apart quickly if it gets wet.

DivineKaos 02-10-2010 07:53 PM

Pics?

10char

frenchlayer 02-11-2010 07:12 AM

Quote:

Originally Posted by uni (Post 8793398)
sweet i'd make one if i didnt have the tuffy already.

feel free to send me the tuffy and then you can build away:2thumbsup:


The time now is 07:54 PM.

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