‘68 Polara Bench Seat console Christmas break build

[HWYCRZR]

I have a few days of vacation to burn off this year and am off between Christmas and New Years so I decided I could/should build an arm rest and cup holder console for long road trips in my bench seat Polara. The key is that it has to be easily removed and doesn’t slide around.
Yes I found some on the internet and even found one I could send some matching vinyl to. The ones I like seem to be around $130, so I figured I am entirely capable of doing one myself and likely to spend much more.
This is my backup plan.
Dodge Consoles & Cup Holders w/ Storage | CupHoldersPlus

Here’s what I have to work with. About 8” wide should crowd me, and about 9” high seems to be a good rest height. I am 6’3”.

Space and and initial layout.

 

[HWYCRZR]

Initial cardboard prototype, to get an idea of space claim and height. A little too big and bulky especially when I have my sheep seat pads in. The cup holder also gets a little too wide. Maybe if I narrowed it a little and actually angle down the top/lid? Also need to contour to the back of the seat.

 

[HWYCRZR]

As I sat cutting it down I ended up with this.

Then I started thinking about the width of the side by side cup holder, my throttle leg will rub against it. So why not utilize floor space as well. So I started working on some contours. But the hump is offset to the left, meaning I will need to do some custom work on that side and keep it away from the gas pedal. Thinking.......

 

[HWYCRZR]

How to get the perfect contouring and fill in for the hump offset?
Am I crazy, could I use plastic wrap and spray foam to create a form fitting base? I wonder how much spray foam it would take?
I could either use it as a base that could be Upholstered or as a contour pattern. I may have to experiment. The spray foam is nasty stuff that wants to stick to everything. I think I need to cover the interior with a plastic drop cloth.

 

[saylor]

if you want to really really form it to fit look at fiberglass. tape a trashbag down tight over the hump then use chickenwire or a blanket or t-shirt to make your shape then paper mache it with fiberglass.

i just kinda hacked some wood into a sortacircle i think i used a 2gal or 5gal bucket shape or something as a sorta guide i dont remember.

try not to die -

- saylor

 

[HWYCRZR]

My attempt with expired spray foam. One from 2011 and one from 2017. I will let it dry and see what shape I get.

 

[Darby]

Many years ago my son wanted a sub box and couldn't find one to fit the space available. When he asked me if we could make one, I told him to make it out of cardboard and leave some room for fiberglass. He cut out a couple versions before landing on just what he wanted (same as you!). After duck-taping it all together and fitting the speakers in we cut the fiberglass sheets and mixed up the resin. We put a couple piece at a time on the box and spread the resin on it. After doing this several times to box was completely covered with several coats of fiberglass on all sides. He used some body filler to finish it off and painted it. It looked awesome and worked well the whole time he used it.
I think what you're doing is great!! If the front of it came up to the bottom of the dash, there could be a way to fasten it to the bottom lip on the dash, hidden from sight when removed.
Just an idea, good luck and show us what you come up with!!

 

[HWYCRZR]

I haven’t spent much time with fiberglass, besides patching a boat. I didn’t like it. I am more of a wood guy for a base. But I will get my contouring how I want it and then build up from there. I need two cup holders and a phone stand. Although the lower dash has a perfect lip for my phone/navigation to sit in landscape mode.

 

[Darby]

I haven’t spent much time with fiberglass, besides patching a boat. I didn’t like it. I am more of a wood guy for a base. But I will get my contouring how I want it and then build up from there. I need two cup holders and a phone stand. Although the lower dash has a perfect lip for my phone/navigation to sit in landscape mode.

I agree with using wood, I thought my son should have transferred his mold to wood, but he didn't want to.
I think you might need to make more than one, there could be a market for it!!

 

[69PHOENIX]

G'Day, Just bought one of these Myself.
8 Litre Capacity, Keeps Drinks Cold & Hot Food "Warm"? On Special at my Local REPCO Store for A$45.00 (Approx US$30.00)
Holds 6 - 8 Cans, Comes with a Plate to Mount Where Ever you Want.
Tony.M
(Sorry if there is a Double Up of the Piccies)

 

[HWYCRZR]

Spray foam somewhat effective. At least it held my boxes together although with a little twisting. I went through a number of iterations.

I think I am getting too big and bulky.
It is helping lay out my zones of reach.
Cup holder is too low after reaching over console.

 

[HWYCRZR]

Moving the cup holder up and back helps. Key is to keep cup far enough away from the steering column but within easy reach and not blocking dash controls or ashtray. I don’t use the ashtray, but it is just the principle. Getting closer. Cup holder is too wide.

 

[HWYCRZR]

Still big. I don’t need the hump support. It will now sit 100% on the seat. Making it easier to install and remove without hitting the dash. I can also restrain it with two elastic? Straps. One to the rear of the seat through the split. I don’t have middle seat belts. And one to the front.
I ordered some cup holder inserts, now I need to better figure out the space claims using those dimensions.

I would love to find some small plastic inserts for change and cell phone holder, but not liking anything I am finding as most are too big. I guess since the whole thing is removable I can dump it upside down to clean it out. Maybe I need to learn how to make silicone molds to make some trays.

 

[HWYCRZR]

Starting my cup and tray layout. Getting closer, refined down a little smaller. Still a little long.

 

[HWYCRZR]

Last picture gave me some ideas. I don’t need 3 cup holders. Maybe I can shrink the lower leg even more.
This is becoming a Heinz 57 or WD-40. This is about BSC-15. Bench Seat Console iteration 15.

I need/ want to have my cup holders on the second level, and put a tray/cell phone holder closer to the dash. I can reduce the bulkiness even further. I think I am ready to start tracing the edge profile to a hardboard template. I think I will use 1/4” Baltic birch plywood. Very stable and consistent. Plus unlike hard board it retains staples and fasteners better than hardboard.

​

 

[HWYCRZR]

G'Day, Just bought one of these Myself.
8 Litre Capacity, Keeps Drinks Cold & Hot Food "Warm"? On Special at my Local REPCO Store for A$45.00 (Approx US$30.00)
Holds 6 - 8 Cans, Comes with a Plate to Mount Where Ever you Want.
Tony.M
(Sorry if there is a Double Up of the Piccies)

View attachment 423994

That is kind of cool. My fear would be the heat it may generate to cool. With no A/C I don’t need any more heat in the car.
For cool beverages a small “Eski” (cooler) in the backseat is enough. My main goal is a padded leaning post with cup holders. Storage is s secondary. I did buy a similar but larger version for my dad to put on his boat a few years ago.

 

[Mr C]

I love your posts. I learn so many great techniques from you that I will use on my Imperial.
Thanks!

 

[HWYCRZR]

Transferred the pattern from cardboard 3 d mock-up to 2d hardboard. Time to make the Sid profile pattern and then I can use my router and pattern bit to get both sides equal. I still have some engineering to do as far as the hinge, box overlap and upholstery.
I think I have the curve figured out. I will rip thin strips of the plywood top and glue to a piece of canvas or even vinyl to make the curve. Since it will be covered with foam and vinyl it will work fine. I don’t think I need to steam it.

 

[HWYCRZR]

Wood pattern cut out and sanded to fit. My side is a little flatter than the passenger side.
Next step is to cut out the sides in the Baltic birch and create my box structure.
I think I can use a hidden piano hinge for the lid.

 

[live4theking]

Nice work