Ok here is a build log of my new center console. This is made entirely from fiberglass from scratch. There is a little bit of mdf included for spanning a large opening and closing off part of the console for a speaker enclosure.

Gotta have a shape so I got me some of the sheet insulation from Home Depot and began cutting strips about 9" wide to fit between the seats. I built it up to form the overall form. Then I began sawing, cutting, shaving, and sanding to get a more defined shape.

The speaker ring was cut from 3/4" MDF with my router and a home made circle jig. You can see it sitting in the general location where it will be when complete. Now I began to coat the form, known as a "plug" with drywall mud since it is easy to spread and sand. Once the DW mud was sanded down I added some Dyna de-Lite body filler to fill in low spots.

More sanding and shaping of the plug to get her smooth. Once I had it like I wanted, I covered the plg in blue painters tape to protect any exposed foam and give it the final shape to the speaker ring. I could have used fleece, but was afraid it would not hold to the foam when stretched tight.

Here you can also see the bezel I made from 1/4" MDF for the shifter opening. Once taped I began laying down the figerglass layers. I put abut 3 layers on the entire plug and let it cure. Then I removed the plug by cutting out the foam, once it was in shell form I began to lay more layers "inside" the shell. This kept the console at the size I wanted yet let me make it thicker for strength.

Here you can see the dark areas where I added more layers of glass and some resin on the outside. The board in the bottom left pic is a separator for the sub area, the bottom got another board and was then glassed on the inside to seal it. Once it was thick enough I began to put filler on the outside which enabled me to smooth it all out.

Here it is in primer and below is a test fit pic . . .

I then sprayed with two heavy coats of Rust Brown primer and installed all components, it was then installed for a month or so to see if I really liked it and wanted to keep it this way. The next pictures say it all . . .

My Speaker

Drying and the final finish - hammered metal texture - I likes

Installed Pics:

Well that is all for now.