PDA

View Full Version : DIY Hacked OEM Shorty Console



jnshk
02-23-2012, 08:12 PM
What follows is some info on my DIY shorty console, as requested. I'm going to present it in evolutionary steps, but I'll also include some notes of things that I've learned along the way.

Part 1 (12-28-2007):

I haven't been entirely happy with how the OEM center console interferes with my elbow during driving, so picked up a spare center console on the cheap and since I had some time off on X-mas day I got to work. Mostly this project was just winging it, and I'm pretty pleased with the results considering the lack of a clear direction.

Basically, I cut the stock console off where the cupholder/ashtray area begins, and then attached the power window switch mounting area (which was also removed from the console via Dremel) to close off the new shorty console.

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0602%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0602x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0603%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0603x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0605%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0605x.jpg)

How to attach the pieces was another lucky accident. While cutting the plastic I noticed how prone it was to melting and sticking to itself, so I took a Zippo lighter to it and sure enough I was able to get it to form a bond. NOTE: It's actually rather difficult to get the right amount of melting without just burning the plastic. My updated recommendation for attaching the pieces is to use a product like "Rapid Fix" glue and filler.

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0606%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0606x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0607%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0607x.jpg)

Testing fitment:

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0609%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0609x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0613%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0613x.jpg)
(Please ignore the pink steering wheel. That was just a temporary fix.)

jnshk
02-23-2012, 08:18 PM
Part 2 12-28-2007:

Once I got a basic shape fleshed out and test fit, I took a propane torch and went nuts on it. A few hours and some scorched fingertips later, I had a fairly sturdy piece. (I discovered that the most effective way to shape and bond the hot plastic was by using my bare fingers, unfortunately.) NOTE: Again, I suggest using a proper chemical bonding agent.

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0614%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0614x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0615%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0615x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0617%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0617x.jpg)

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0618%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0618x.jpg)

I attached a tab at the back side to use the middle attachment screw in from the original console. Unfortunately, I didn't do a very good job and it's already begun to crack. I will have to redo it later, and maybe try to make it look more attractive as well.

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0620%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0620x.jpg)

I originally planned to use the OEM power window switch, but with the way I attached things, the bottom of the switch extended below the edge of the console, which created a gap at the back/bottom edges. I picked up some switches (mom-on/off/mom-on, double-pole) from NAPA and mounted them in the switch panel blank that had come with the spare console. With some gentle tweaking of the angle on the bottom terminals, they gave me just enough clearance for the console to sit relatively flush against the driveshaft tunnel. They seem to work just fine.

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0621%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0621x.jpg)

I also ended up having to drill a few holes to mount the shift boot as well, since I accidentally melted one of the threaded sleeves beyond use.

http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0619%20(WinCE).jpg (http://somethingsquare.com/temp/project_fail/shorty_console/IMG_0619x.jpg)

The camera flash really brings out the imperfections. It actually looks a lot better in person than in these pictures, but I will probably replace the mounting screws with some black allen head screws for a nicer appearance, and I'd like to see if I can do something to clean up the finish of the console as well. I'd prefer to get it looking as clean and OEM as possible if I can, but for now I've got more important stuff to do first. :(

jnshk
02-23-2012, 08:21 PM
Part 3 08-06-2008:

NOTE: This method of securing the end of the console worked and looked OK, but it was a real PITA to deal with. I recommend just attaching a flap with a bonding agent (see later stages of this project) instead.

I finally got around to making some changes to the way that the rear of the console is secured. Not only does it look nicer, but it is also far more secure than before.

I cut off the old tab (which was cracked badly enough that it would probably have broken off soon anyhow) and re-shaped the back edge a little bit to smooth it out.

http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1397s.jpg
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1399s.jpg

After mocking up a bracket with cardboard, I managed to fabricate something similar out of metal.

http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1404s.jpg
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1405s.jpg
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1409s.jpg

Painted the new bracket and re-painted the console.

http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1410s.jpg

And added a more attractive P/W override switch (the green ring is wired to illuminate with the interior lights).

http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1414s.jpg
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1415s.jpg

Installed in the car:
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1419s.jpg
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_1420s.jpg

The shorty console is darker than the stereo console, but it should lighten/fade a bit and match better after a week or two in the Texas sun.

jnshk
02-23-2012, 08:26 PM
NOTE: My final solution was new carpet (which is not precut with any holes) from StockInteriors.com, but that's because my old carpet was destroyed by weatherstripping leaks and a clueless previous owner.

My initial solution to the exposed release levers:
http://www.somethingsquare.com/temp/project_fail/shorty_console_2/IMG_2391m.jpg

I took some old black floor mats and cut the corner off one of them, put a slit down the center, and slid it over the levers. It may not be super classy, but it's not bad for a cheap/free project. :) (I also took some of the floor mat and cut small pieces to go under the trans tunnel carpet where the holes for bolting down the console were. Again, not perfect, but it makes it slightly less noticeable until I come up with something better.)

jnshk
02-23-2012, 08:35 PM
Part 4 11-27-2011:

Finally got around to making some more changes to my shorty console and power window switches. I think that Version 3 will be the final version. The only changes I might be willing to make at this point would be to fill/sand/smooth and repaint it since there are still a few rough spots.

http://www.somethingsquare.com/temp/project_fail/shorty_console_3/IMG_6874s.jpg

http://www.somethingsquare.com/temp/project_fail/shorty_console_3/IMG_6875s.jpg

http://www.somethingsquare.com/temp/project_fail/shorty_console_3/IMG_6876s.jpg

I added a new flap-tab-thing to hold it down rather than that bulky contraption, and this seems to be much nicer. I took some scrap ABS plastic sheet and used "Rapid Fix" glue and filler powder to firmly attach the tab to the end of the console. This method is far easier than plastic welding, and appears to be exceptionally strong as well.

ChrisJuliano
02-23-2012, 09:02 PM
Very nicely done! I think Morr will like this he has been talking about one recently.

morr
02-24-2012, 09:31 AM
^Haha yep! Thanks for the writeup jnshk. I'll be attempting this project soon enough.

RyanxStorey
02-24-2012, 09:34 AM
One of the best things added to this site. This will be very helpful to others. Thank you.

diabeetus
02-26-2012, 08:38 PM
oh hellya! i am gonna hit the junkyard soon to grab me an extra console!! yours look amazing!! damn

diabeetus
02-26-2012, 08:40 PM
what is that little button in between the shifter and the window switches?

jnshk
02-27-2012, 03:15 AM
Normally the power windows only work when the key is in the ignition. That button is a momentary push-button switch that I've added with a relay so that I can push in on that while pushing the toggle switches to roll the windows up or down without the key being in the ignition.

KJMagnum
01-13-2013, 11:33 PM
Aw, I was finally going to do this and now your site is gone along with the pics :(. Any chance of rehosting them?

Agent☣Orange
01-14-2013, 11:43 AM
Agree. :(

maharaj
01-14-2013, 12:04 PM
Pics please.

91BRGLE
01-14-2013, 12:32 PM
Where did you get that switch? (the momentary one) Thats the best shorty I've seen, great work!

wannafbody
01-14-2013, 06:08 PM
Revlimiter makes those window switches

91BRGLE
01-15-2013, 11:31 AM
Revlimiter makes those window switches

I mean the single one above the rev limiter ones.

jnshk
01-15-2013, 09:10 PM
Pics should be back. My hosting company was upgrading the server that my site is located on, so there was some downtime during the transition.

The momentary pushbutton switch was obtained from ebay (some random chinese company). It was originally intended to be the start button in my Volvo, but the dimensions on the auction were misprinted and when it showed up and was about 1/4 of the size it was supposed to be I was not amused. It would have cost more to ship it back to China than my refund would have been, so I stuck it in my box of goodies until I had a use for it. So glad I did too, because it really suits the car!

I'm pretty sure this is the switch that I used: eBay--1pcs Stainless illuminated Momentary switch-green(19mm) (http://www.ebay.com/itm/1pcs-Stainless-illuminated-Momentary-switch-green-19mm-/200402515030?pt=LH_DefaultDomain_0&hash=item2ea8ebb456) I think it was cheaper back then, but that was at least 5 years ago, so...

And if anyone cares, here's what eventually did go into the Volvo:
http://www.somethingsquare.com/temp/volvodrftr/start/IMG_0064%20%28Small%29.jpg

Illuminated arcade start button!

91BRGLE
01-16-2013, 08:08 AM
Thanks! Best shorty and now best start button!

Heyitsryan
01-16-2013, 10:26 AM
This looks awesome, any chance I can drive over to where you are and you can help me make mine? lol

jnshk
01-16-2013, 07:42 PM
Haha, I don't know about making yours, but I could definitely drink beer and watch while you burn your fingers making it yourself... :P

Actually though, if we can ever finish some of our remodeling projects and get the house/garage cleaned up, I'd love to host a Miata "wrench day" where people could bring their food, drink, and car parts and everyone could chip in on some cars to get some free/cheap labor. Sadly, it's going to be a looong time before the house is ready for that at the rate we're moving.

jnshk
03-24-2015, 06:05 AM
Just thought that I'd update this with another tip/technique. I believe the console is made from a plastic which can be dissolved by acetone, so an alternative to the "RapidFix" glue would be to dissolve some of the scrap parts of the console into a small amount of acetone (use a glass jar with a lid that seals tightly!) and make your own plastic "cement" goop mixture. If you make it thin, you can brush it on and then press/hold the parts together and they should bond. If you make it thick enough, you can fill some gaps. My experience is that if it's thin you don't want to use large quantities as the mixture will shrink substantially when the solvent evaporates, leaving bubbles.

*Note: When working with acetone, always work in a well ventilated area and follow proper safety precautions as per the instructions on the product. Also, I'd suggest playing/practicing with the scraps before trying to assemble your final piece.

Airbrush1
03-26-2015, 09:22 PM
Pro-tip, acetone smells awesome!

Good job on the console, I have a spare laying around that I've been meaning to mess with

NCGreasemonkey
12-24-2015, 09:50 AM
Now you have me wanting a "shorty". Will have to head to U-Pull-It after the holiday.

Axt3365
01-24-2016, 10:04 PM
Here's a couple of the one I made for my girlfriends 95 M edition. Fits nicely if I say so myself and especially with her Italvolanti wheel ��
154631546415465

RuckkehrMiata
01-24-2016, 10:08 PM
Here's a couple of the one I made for my girlfriends 95 M edition. Fits nicely if I say so myself and especially with her Italvolanti wheel ��
154631546415465

You made them? If from scratch those are really nice!

Axt3365
01-24-2016, 10:26 PM
Yessir! Hacked up a stock console and formed the end of it! Plastic welded the switch mount then fiberglassed it in.
15466154671546815469

NbSteve
08-20-2016, 03:58 AM
Sorry to revive an old thread but is there a writup on the window override?! I'd love to do this


Sent from my iPhone using Tapatalk

jnshk
09-16-2018, 02:13 PM
Sorry, for such a late response, but I don't log in to the forums much anymore. I don't have any DIY for this and it's been a very long time since I did it, so I can't give you exact details, but I can give you the general process:

1. Find a source for 12v constant power. You can use an "add-a-fuse" kit to tap into an appropriate source at the fuse panel, or you can run a (fused) power wire all the way from the battery. Make sure you use a suitable gauge of wire and fuse for the power window circuit.

2. Get a "momentary on" and off switch. This can be a push button, toggle, rocker, whatever. Just make sure that it's mom.on-off. This way the windows can only be rolled up/down while pressing/holding the override switch unless the ignition is on. If you really wanted to, you could use a regular on-off switch, but that would make it so that you'd have to remember to turn the switch off to undo the bypass. I suppose if you really wanted to you could do a permanent bypass by just not using a switch at all.

3. Use a relay. Unless your chosen switch can handle a pretty high current, it is recommended to use a relay to supply the power triggered by your switch. You can source positive power for both the switch and relay from the constant 12v wire that you already set up in step 1. If you're not sure how to wire up a standard relay, I'll let you google it. There are a few different common approaches that work.

4. Hook your triggered override power to the 12V-IGN power wire in the power window harness. In my '97 (and most other year models, I believe) it is the black wire with white stripe. Depending on what modifications if any you've already made (such as a DIY power window switch assembly), you'll have to determine the best method for splicing in for your install. It wouldn't be a bad idea to wire in a diode that prevents the override power from backfeeding into the 12V-IGN circuit, but if you don't know how to do that I'm not going to get into it here. I can't recall whether or not I even bothered to do it on my install.