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Center Console Project

From 1986 Ford Bronco, documented by Rodolfo Mario Novo.

32 photos
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1986 Ford Bronco - I have a Bronco.... 1986 Ford Bronco - ...and my garage is a mess.... so I think I qualify to post this write-up. 1986 Ford Bronco - As usual, first thing is to make some templates. Templates need no much precision because you only use them to cut the piece of polyurethan… 1986 Ford Bronco - Using the cardboard template as a guide cut a piece of foam. Be generous while cutting because you can cut or sand the excess material late… 1986 Ford Bronco - Final shape, all parts glued together. 1986 Ford Bronco - Some minor trimming is required to get a flat surface in the bezel 1986 Ford Bronco - And there it goes...the bezel fitted in the console.... 1986 Ford Bronco - A center console structure with cream-colored foam padding and a black plastic frame, sitting on a workbench during a restoration. Househol… 1986 Ford Bronco - A black plastic center console frame or dash structure surrounded by shaped foam padding, sitting on a workbench in a garage or workshop se… 1986 Ford Bronco - A black plastic interior dash bezel with a large rectangular opening, packed upright in custom-cut cream foam blocks as if for shipping. It… 1986 Ford Bronco - You can see in the pictures the different parts I bonded to obtain the final shape. 1986 Ford Bronco - First approach in the vehicle...After hours and hours of sanding, cutting bonding and again sanding I got this. You can see that I tried to… 1986 Ford Bronco - Interior view of a custom center console under construction, showing raw fiberglass or foam bodywork in off-white with black plastic shifte… 1986 Ford Bronco - Detail of the slot. This was the tough part of the job. Many tests and lots of coming and going until the final match was achieved. Later o… 1986 Ford Bronco - Once I was more or less satisfied I started fiberglassing the foam. Please follow the instructions about the proportions while mixing the r… 1986 Ford Bronco - One of the places where the bezel goes. 1986 Ford Bronco - Extreme close-up of a molded cream-colored foam cushion, likely seat foam, with dark stains and stringy spray-adhesive strands along a glue… 1986 Ford Bronco - Prepairing the mat 1986 Ford Bronco - After placing the mat use a brush to apply the resin. You can apply 2 hands of resin and 2 layers of fiberglass and after that let it dry.… 1986 Ford Bronco - A custom part being fabricated from shaped cream-colored foam with fiberglass cloth draped over it and resin along the edges, sitting on ne… 1986 Ford Bronco - When fiberglassing around edges I found helpful to make some cuts to help the mat following the shape. 1986 Ford Bronco - Close-up of white fiberglass matting laid over newspaper on a workbench, cut into parallel strips so it will conform to a curved surface. A… 1986 Ford Bronco - When you finish fiberglassing all the external part of the foam, places where the bezel will fit and the parts where the lever will slide,… 1986 Ford Bronco - A gloved hand works a corded orbital sheet sander over a cream-colored molded plastic trim panel resting on newspaper, sanding down glue li… 1986 Ford Bronco - After sanding you’ll find many imperfections. These are to be covered with polyester resin (the one used by car painters to fix small dents… 1986 Ford Bronco - Painting is not within my skills, so after finishing the shape, I sent it to get painted by a pro. He used special polyurethane paint with… 1986 Ford Bronco - Final product with VHF in place. Gauges will be rady next week and in 30 days original burloak bezel will be here. 1986 Ford Bronco - I don't like the end result in the slot for the 4wd lever but I'll try to improve it 1986 Ford Bronco - Interior view of the center console and floor-mounted manual transfer case/shift lever in a gray-trimmed vehicle, showing the transmission… 1986 Ford Bronco - Interior view of a custom blue-gray center console in a truck or SUV, featuring an open storage compartment and a mounted two-way radio/han… 1986 Ford Bronco - Done. Changed the dash and installed the gauges. Also included a dummy ruber strip to give a finished look to lever slot. 1986 Ford Bronco - I still need to drill a hole to place a new lighter because the old one and the ashtray are hidden by the console.