Thought I'd start a new thread on the fabrication of my dash valence, and more fab work on my console. I've posted a few pics before but I decided to put them here to make it a more complete thread.
My idea is to try to tie the valence into the console like you see on some modern cars. I wanted a smooth flowing curve from the valence to the console and along the console edges. This is my valence design in CAD after a few hours of measuring and massaging it:
I decided to add 4 A/C vents instead of the two at the ends that I initially planned to use. I was going to put two on the side of the console but decided they look better with 4 as long as I can get the hoses fitted. I haven't decided yet if I'm going to retain the stock fresh air vents, and if I do I will need to add the knobs and cables or some electrical actuator. Also, I have a Lokar park brake release knob I need to add somewhere. There may be switches for the power vent windows and other things on the valence too, if I don't put them elsewhere. I don't really want the vent window switches on the door.
I started building my console some time ago, before my door panels were finalized. I'm considering changing the design from the one on the left to the one on the right since it flows with the door design better. It all depends on the aesthetics on the top and the fitting of other parts.
I want to make most of this out of aluminum because I find it easier to work with than steel (I'm not good enough to make it in steel), and I don't like a lot of wood or MDF used for interior construction in a car.
I had some initial thoughts about how to build the valence, and after studying how to fabricate it and getting some suggestions here I decided to round the bottom of it with a mild radius instead of making it square. This will make it flow nicely into my console which will also have rounded moldings on the sides of it if I can make them right. It also gave me a fairly ridid piece to weld to, minimizing distortion.
I laid out the part on some 5052 aluminum, drew the forming lines allowing for a bend at the top to attach it to the dash. Then I started forming it over a 3/4" rod and the edge of a 2x3x.188" tube which seems to have a 3/8" radius on the corners. I used a plastic hammer and a steel body hammer. The 5052 forms pretty well but it does work-harden fairly fast. Once it was formed, the whole part was severely curved due to the stretching caused by forming so I had to shrink the formed edge to make it straight again.
After the main piece was formed to my liking, I cut the piece for the lower flange making it wide enough to transition into the console molding that I will fab later. I bent it over some round objects in my shop by hand, to get it close to the shape of the valence. I also clamped the valence to my tubing to help keep it straight while welding the flange on.
This is what it looked like after welding and grinding...
After trimming and initial fitting it looked like this:
Next I drew up some A/C vents actual size (1.6"x4") to see what it looked like, and if I liked the way it was turning out. I also installed an old instrument cluster I had as well as a 2" stainless tube to mock up the steering column and the windlace retainer.
At first it seemed kind of tall to me, but after drawing in the trim I plan to add along the top, and sticking the fake vents on, I think it works out just about right. It just takes a little getting used to after having nothing there. I haven't figured out what to do with the end at the console yet. There will be a DVD stereo there with a bezel that doesn't leave a lot of room.
Now I have to finish fabricating the passenger side. The trim on top will probably be stainless steel. The dash will be charcoal all the way down to the valence. The valence might be orange, to bring the exterior color into the car. Or I may make the top of the console orange, and put carbon fiber on the valence to match the door moldings.
Please let me know what you think if this as I appreciate all feedback.
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Originally Posted by MP&C
