SUNP0106 (Medium).JPG
456 hits | 60.69 KB | Posted: 2006-10-29
(Posted in: Jeep)

Cragars(Medium).JPG
513 hits | 60.13 KB | Posted: 2006-10-29
Mmmmm.....Cragars........
(Posted in: Jeep)

SUNP0153 (Medium).JPG
441 hits | 49.09 KB | Posted: 2006-08-25
Trace the template cut it out!

Now that you know how to do one panel, you can figure out how to do the rest....
(Posted in: Jeep)

SUNP0152 (Medium).JPG
479 hits | 44.52 KB | Posted: 2006-08-25
Tape them together and lay them on your plywood....
(Posted in: Jeep)

SUNP0150 (Medium).JPG
462 hits | 28.81 KB | Posted: 2006-08-25
Now we have the original and the filler piece that will fit together to form the template for our side piece....
(Posted in: Jeep)

SUNP0147 (Medium).JPG
434 hits | 28.51 KB | Posted: 2006-08-25
Now with both pieces on a semi-flat surface (like, say, the hood of your xj), line them up using the line you drew.

Flip them over and draw the line where the bottom of the original meets your patch panel....
(Posted in: Jeep)

SUNP0146 (Medium).JPG
377 hits | 28.82 KB | Posted: 2006-08-25
Again, I only have the 2 hands, so use your imagination.

What we have to do to correct the gap is this: using some method of your choosing (I used masking tape and one hand), hold the original cardboard template flush with the bottom of the base. Then take another piece of cardboard which is the right length and angle it so that it is flush with the floor.

Mark the line where the two pieces meet....
(Posted in: Jeep)

SUNP0145 (Medium).JPG
457 hits | 27.08 KB | Posted: 2006-08-25
Oh Noes!!! What's this?

The transmission hump is not perfectly flat, so the base piece is not actually sitting flush with the floor. We can't have that, because then the finished console will look.....what's the word......ghetto-fabulous?...
(Posted in: Jeep)

SUNP0144 (Medium).JPG
501 hits | 32.94 KB | Posted: 2006-08-25
Looks pretty good, eh?...
(Posted in: Jeep)

SUNP0143 (Medium).JPG
381 hits | 32.95 KB | Posted: 2006-08-25
So then we take the silver solder and lay it on a piece of cardboard and trace it. Here we have the entire passenger side forward panel already cut, with the silver solder showing that our contour matches....
(Posted in: Jeep)

SUNP0141 (Medium).JPG
352 hits | 36.17 KB | Posted: 2006-08-25
Now you have a pretty darn good approximation of the contour you need to cut in the wood....
(Posted in: Jeep)

SUNP0140 (Medium).JPG
345 hits | 30.22 KB | Posted: 2006-08-25
...and push it to the rear. I only have 2 hands, so I couldnt take a picture while I was making the contour. Basically you hold the short end of the L with one hand and bend the long end with the other as you push towards the contour. ...
(Posted in: Jeep)

SUNP0139 (Medium).JPG
307 hits | 33.32 KB | Posted: 2006-08-25
Line up the short edge of the L with the bottom of the base piece......
(Posted in: Jeep)

SUNP0137 (Medium).JPG
332 hits | 37.11 KB | Posted: 2006-08-25
then you bend it into an L shape......
(Posted in: Jeep)

SUNP0136 (Medium).JPG
293 hits | 37.75 KB | Posted: 2006-08-25
Now, on to how we are going to make the back of the console match up to the contours of the dash.

First, you take your silver solder......
(Posted in: Jeep)

SUNP0131 (Medium).JPG
325 hits | 39.4 KB | Posted: 2006-08-25
Here is the first piece I cut. I fiddled with cardboard cutouts for many hours before making this first cut, and as you can see it came out pretty well...
(Posted in: Jeep)