TJ Overhead Console Build Thread - JeepForum.com
Search  
Sign Up   Today's Posts
User: Pass: Remember?
Advertise Here
Jeep Home Jeep Forum Jeep Classifieds Jeep Registry JeepSpace Jeep Reviews Jeep Gallery Jeep Clubs Jeep Groups Jeep Videos Jeep Events Jeep Articles
Go Back JeepForum.com > General Technical Discussions > Fabrication Shop > TJ Overhead Console Build Thread

End of Summer Sale, 20% OFF!Introducing MONSTALINER™ UV Permanent DIY Roll On Bed LineRough Country Jeep Suspension Deals at Rockridge 4WD!

Reply
Unread 01-25-2010, 11:43 PM   #1
FlyinPhil
Registered User
2005 TJ Wrangler 
 
Join Date: Aug 2009
Location: Edmonton AB, CA
Posts: 221
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



planning stuff out



cutting one of the sides



the two identical sides next to each other



The maxitrip



a quick mock up of the stereo and computer



Glueing.....the more clamps the better



Deciding what to do for the switch panel



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



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 )



cont....

__________________
A 6spd makes it a race car right?
FlyinPhil is offline   Reply With Quote
Unread 01-25-2010, 11:44 PM   #2
FlyinPhil
Registered User
2005 TJ Wrangler 
 
Join Date: Aug 2009
Location: Edmonton AB, CA
Posts: 221
holes drilled and hardware added to the switch panel housing



CB pics







here is a better mock up



hooray for sheet metal



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










cont...
__________________
A 6spd makes it a race car right?
FlyinPhil is offline   Reply With Quote
Unread 01-25-2010, 11:44 PM   #3
FlyinPhil
Registered User
2005 TJ Wrangler 
 
Join Date: Aug 2009
Location: Edmonton AB, CA
Posts: 221
brackets bolted to the crossmember ( c channel aluminum )





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



ribbed supports



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



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



clean stereo harness



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



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

__________________
A 6spd makes it a race car right?
FlyinPhil is offline   Reply With Quote
Unread 01-26-2010, 10:22 AM   #4
DC4W-93XJ
Registered User
1990 XJ Cherokee 
 
Join Date: Oct 2008
Location: Grand Junction, Crawlorado
Posts: 579
VERY nice.... i think i've been inspired...

i think an MDF model would be much cleaner.. nice work..
__________________
THIS AIN'T YOUR MAMA'S STATION WAGON!!
Built Jeep Tough With Chevy Stuff
"Tater 2" '91 2 door XJ chopped and bobbed, 4.0, AW4, dana 300, GM 60/70HD, 40" IROKs on H1s
SEE THE BUILD HERE
DC4W-93XJ is offline   Reply With Quote
Unread 01-26-2010, 10:23 AM   #5
DC4W-93XJ
Registered User
1990 XJ Cherokee 
 
Join Date: Oct 2008
Location: Grand Junction, Crawlorado
Posts: 579
any installed pics??
__________________
THIS AIN'T YOUR MAMA'S STATION WAGON!!
Built Jeep Tough With Chevy Stuff
"Tater 2" '91 2 door XJ chopped and bobbed, 4.0, AW4, dana 300, GM 60/70HD, 40" IROKs on H1s
SEE THE BUILD HERE
DC4W-93XJ is offline   Reply With Quote
Unread 01-26-2010, 10:43 AM   #6
MO2500
Fabramicator
 
MO2500's Avatar
1997 TJ Wrangler 
 
Join Date: Mar 2009
Location: MoCo, MD
Posts: 6,582
that looks really nice installed pics please
__________________
My Jeep Build
Useful tech links:
Stu-Offroad - great technical write-ups!
What's a CV shaft and why do I need one?
Driveline 101
TJ Specs
-Mike-
MO2500 is offline   Reply With Quote
Unread 01-26-2010, 10:56 AM   #7
5.7YJ
Senior Member
 
5.7YJ's Avatar
1987 YJ Wrangler 
 
Join Date: Aug 2006
Location: Rockledge, Florida
Posts: 900
Looks great, please post some more pics!
5.7YJ is offline   Reply With Quote
Unread 01-26-2010, 11:04 AM   #8
FlyinPhil
Registered User
2005 TJ Wrangler 
 
Join Date: Aug 2009
Location: Edmonton AB, CA
Posts: 221
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!
__________________
A 6spd makes it a race car right?
FlyinPhil is offline   Reply With Quote
Unread 01-26-2010, 11:05 AM   #9
TennesseeTJ02
Registered User
2002 TJ Wrangler 
 
Join Date: Nov 2009
Location: Knoxvegas, Tennessee
Posts: 111
looks great!
TennesseeTJ02 is offline   Reply With Quote
Unread 01-26-2010, 11:07 AM   #10
FlyinPhil
Registered User
2005 TJ Wrangler 
 
Join Date: Aug 2009
Location: Edmonton AB, CA
Posts: 221
Quote:
Originally Posted by TennesseeTJ02 View Post
looks great!
Thanks! there will be more pics soon
__________________
A 6spd makes it a race car right?
FlyinPhil is offline   Reply With Quote
Unread 01-29-2010, 10:57 PM   #11
Unii
Registered User
1995 YJ Wrangler 
 
Join Date: Feb 2009
Location: Cleveland, Tennessee
Posts: 1,272
sweet i'd make one if i didnt have the tuffy already.
Unii is offline   Reply With Quote
Unread 01-30-2010, 09:49 AM   #12
JWitt333
Registered User
1999 TJ Wrangler 
 
Join Date: Oct 2007
Location: Near Galveston Bay, Texas
Posts: 526
that looks really good. too bad for the cat though.
__________________

'99 Gunmetal TJ
Blue Jeep Club Member #256
4" RC X-Series, 1in BL
Rokmen Armor
KC Day Lighters, 33 BFG M/T
with more to come
OlllllllO
JWitt333 is offline   Reply With Quote
Unread 01-30-2010, 07:07 PM   #13
bdevr
Registered User
1997 TJ Wrangler 
 
Join Date: Nov 2008
Location: reno
Posts: 202
Quote:
Originally Posted by DC4W-93XJ View Post
VERY nice.... i think i've been inspired...

i think an MDF model would be much cleaner.. nice work..
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.
bdevr is offline   Reply With Quote
Unread 02-10-2010, 07:53 PM   #14
DivineKaos
Registered User
2000 TJ Wrangler 
 
Join Date: Jul 2009
Location: Saint John, New Brunswick
Posts: 506
Pics?

10char
__________________
"A man has to know two things in life, limitations and priorities. You let your priorities get in the way of your limitations." - MrBlaine
DivineKaos is offline   Reply With Quote
Unread 02-11-2010, 07:12 AM   #15
frenchlayer
Registered User
2010 JK Wrangler 
 
Join Date: Feb 2004
Location: Atlanta
Posts: 245
Quote:
Originally Posted by uni View Post
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
frenchlayer is offline   Reply With Quote
Reply
Thread Tools


Suggested Threads





Jeep, Wrangler, Cherokee, Grand Cherokee, and other models are copyrighted and trademarked to Jeep/Chrysler Corporation. JeepForum.com is not in any way associated with Jeep or the Chrysler Corp.