New Console Build

RyanPratt · 31 August 2018, 01:55

Building a new Jockey Console.

RyanPratt · 31 August 2018, 01:57

adding a little more detail

RyanPratt · 31 August 2018, 02:00

Still more detail, making a real mess with this foam.

RyanPratt · 31 August 2018, 02:05

Cover this baby up! fell short on the photos of this step, to much frustration. Not the fun part of a build.

jeffstevens763@g · 31 August 2018, 11:27

hi Ryan can you give a bit more detail is it closed cell foam your using and what are you rounding off with tool wise interesting project

RyanPratt · 31 August 2018, 15:13

I build the spine of the mold using cosa board for stiffness. I then glue 4lb foam in layers to build up the profile. I use a hand rasp, sandpaper a shaper and orbital sander to shape the plug. I also use a standard 3/4 round over router bit for my outside radiuses for consistency. When shaping i mark all the lines on both sides before i start as far as where the profile changes. Then i shape one side and make cardboard templates of the transitions so i can match the best I can on the other side. I fill all low spots with P-77 then i shoot it with duratech and sand, polish, wax. then PVA, GEL, mat stiffeners then mat and thats the process in f fwd.

Hope that helps.

RyanPratt · 31 August 2018, 15:17

Finished coating, sanding making and mold making first part out of the mold

RyanPratt · 31 August 2018, 15:21

Now we need something to sit on. I designed an aluminum seat frame and had a friend water jet and bend it for me. We added a ss stud to the frame to stop the bolt from eating the aluminum. We drill a hole the width of the console and install a threaded aluminum axle to allow for the secure attachment of the frame.