what material to use?

[scoutinkeith]

I'm working on making an overhead console to put in my 93 wrangler. it's going to go from side to side, and mount to the bars that go from the role bar to the windshield frame. the console will hold the radio, CB, switches, and maybe even a couple speekers. over the weekend I made a cardboard mock up, and I think it will work nicely, and not take up to much space, the problem is that I can'd decide what to build the actuail unit with? my options are metal, wood, and accrylic(plexiglass). it will most likely be padded and covered with some type of water-proof material (maybe vynal seat material to match the interior)
I think the metal would hold up the best, but I have enough scraps of both the wood and accrylic lying around that I'm thinking of making it out of one of those just to keep the cost down. what do you guys think, would wood hold up well enough, or should I just suck it up and buy the metal to make the console?
oh yea, another reason I'm leaning towards the wood or accrylic is that I do not yet have a welder.

[fredjacksonsan]

How about mainly acrylic with some metal cross members embedded for support? Best of both worlds, and the acrylic won't rust on ya.

[Saxonwolf]

I wouldn't use wood. Wood is too heavy to be hanging from your roll bar, unless it's a thin plywood and then youre talking about a strength issue that would be difficult to hold a screw or nail.
If you dont have a welder, then metal is out. Im not so sure about using metal anyway. To me metal is difficult to work with.
Acrylic would be good if its strong enough and youre pretty good with gluing. When you say acrylic, do you mean that real thin almost plastic like material? If so then I'd opt for the metal.
The ideal thing to use in my opinion would be about 1/4" thick Lexan, but it can be tricky to work with because now youre talking about glued edges and joints. Not to mention, Lexan is pretty expensive stuff.
How were you planning to attach it to the roll bar?

[JeeperRich]

A basic metal frame with lexan panels can work well. Metal angles are easy to cut with a hacksaw, etc., and are strong and light -- you can bolt them together. Lexan (or acrylic, plexiglass) is light, easy to cut/drill, and can hold bolts well.

[scoutinkeith]

well, I work in a shop that dose work for research labs. I mostly make cabinets and countertops, but I also make specailty equipment out of accrylic, so I can get scrap pieces of the accrylic anywhere from 1/16" up to 1' thick, and have all the tools to form and glue it.
however, at this time, I'm thinking of using some 3/8" marine grade plywood that I have left over from work I did on a boat that I used to have. the wood would be used only for the top piece of the console. then forming the rest of the console from fiberglass, and then covering it to match the interior. I think the fiberglass would give me more flexibility to form it around speekers and such, and also keep the weight down.

as far as mounting, I'd probably just run the top part over the top of both side bars, and bolt it to them, then when it's wrapped with fabric, the bolts would be hidden, kinda like the way the sound bar is mounted.

[CanaMark]

You should build up something to hold the beers. I always use the passenger seat. Wont be sitting in the drivers seat for a few years anyway. Second time around should teach me huh. In the states all one has to do is move across a state line. Ah it should humble me.

[JeeperRich]

Sounds like it'll work -- make sure you waterproof the plywood first to keep it from delaminating.

Post some pics when you're done!

[DanDSN]

I'd like to see some pictures of your project when you are done. I own a 95 Wrangler and I may even be interested in buying one from you if this is possible. I would like to see the finished project first though. Please send me some pictures and let me know if you are willing to possibly make me one. If not I'd still like the pictures so I could have an idea of how to make it for myself.

My e-mail address is [email protected]

Hope it turns out good

Eat, Sleep, and Jeep

Dan

[scoutinkeith]

DanDSN,
I haven't made much progress on the console yet, I've been really bussy with work, and stuff around the house. I did get a cardboard mock up made, and I'm wanting to fine tune it a bit before I sart making the actuail console, and I'm still undecided about what materials to use. but I'll definatly send you some pictures when I get it finished.
Keith