Thread: Just starting custom console in 02 P71 Crown Vic

Here is the console with the lid. Its not yet attached, but the size is perfect. I routed off the front edge first, then took a palm sander to it. Not bad for a jack-leg.:-)
I will glue some thick carpet padding to the top before I put a covering felt on it. I let the front end hang over the switch panel cuz I am gonna mount a very small LED under (into) the lid to illuminate the switch panel. Thats my hope anyway.
I think thats the last of the wood (MDF) parts I need to make. Next is dis-assemble and draw templates.
I hope to resume work on it all day sunday.

==LawnGOD

Another pic of completed console. I will remove all the screws and template each part next.

==Lawn

I really would like to hear what you guys think about the console so far. I am a total n00b at this but I think patience and the right tools are the most important things in a project such as this. I will need to read more about bondo, sanding and painting next. Any and all recommendations are welcome and appreciated. Everything I have learned about this console to date has come from mp3car.com.
Thanks much for all your help,

==Lawn

judging from the apparent burning on every routed edge you have there, i think there's something wrong with your router bit... MDF should be routed with a sharp carbide-tipped bit.

as for the creativity and effort, great work!

Looks very nice! I´m considering redoing my Toyota´s console and your work may give me some important notes and nice ideas. Go on!

I think you are absolutly correct about the router bit. Early in the routing proccess I asked a buddy about that. Told him I really had to lean on the router for it to cut and when I do, it burns like that. He told me router bits dont really get dull and that I could sand off the burned areas. As this is my first effort in routing (wood work routing...:-)), that sounded good to me, so I continued. I will sand the blackened areas to make it look nicer and smooth the routing out. Does the burning cause any long term damage to the MDF? That stuff is VERY dense and hard to cut with a router. Maybe I need a better bit, but I think the routing is done for this project.

Thanks,

==Lawn

i'd say just get the better bit. you can get a good bit from Lowes or HD for about $25 and it will save you all the sanding and eliminate all those ridges and burns. Burnt MDF is a real pain to sand. The heat does something to the binder in there and makes it a real chore. Never underestimate the importance of sharp tools not just for clean cuts but for safety too. You don't want to be leaning on a router bit when the wood slips. Honestly, with a sharp bit, the wood will almost literally glide through.

I will get a better bit before I make anymore cuts. I knew that cheap one from Harbour Freight wouldnt last long.

Here is the unit dis-assembled and in a pile. I numbered then traced each part out onto a large peice of cardboard. Also marked the screw holes and other demensional info required to replicate the console.

==Lawn

This is one of the templates for the parts of the console.