New console build

[stevebrownell]

Subject: New Console Buildup

Scrapped the tired stock console this past spring on the 20SF I/O, decided to start a full restoration, but this was the first project I had time to finish. Basic stuff: plywood, cloth, epoxy. Pics attached are the highlights from construction, and show it in primer. Going to spray w. Interlux this fall. I have the same boat as want2fish, but I'm seriously lagging his progress.

Going to be hydroblasting the hull soon, will post before and after pics once that is complete.

I think some of these shots are too big - should I resize based on the max. size, or just stick w. the 640x480 pixel standard? Sorry if this looks like crap....

First panel:


Skipping ahead a bit - rough carcass assembled. Control panel is 2 layers of plywood, wanted something sturdy. Everything was cabosiled together, 2-4 layers of 9 oz cloth tape to reinforce corners, 4 oz cloth inside and out:


Side view - my dimensions were based on what I think will work best for the limited space on each side - this piece is about 28" wide, vs. around 36 for the original. Console is roughly 4' tall, vs. the orig. which was way too low. I'll wrap a short windscreen around the top when done. This will also bring the controls up some; instruments closer to eye-view too:


Front - some fairing needed:


In primer, testing wheel fit, short grab rails. Steering is backed up with 2 inches of laminated marine ply. One of the weak spots on the teleflex install on the last console was in that area:


With controls installed, test fit sounder and mini-switch panel:


Another shot, testing layout of gauges -went with another cluster layout in the end:

[ScottM]

Steve,
The console looks really nice. Your pics are the perfect size too. 640x480 seems to be the best size.

[warthog5]

I agree with ScottM. 2in thickness where the helm is, is a little extreme.

[stevebrownell]

Wart/Scott: thanks for the kind words. I hear ya' 2" thick on the console face would be overkill!

Problem is that the teleflex bracket forces you to drill the mounting holes within one bolt diameter of the cutout - there just does not seem to be enough material to support the side to side loads you have on the wheel, especially when it acts like a defacto hand-hold on my leaning-post-less CC. I was not clear in my first post - only the console face is one inch thick, but the backer plate for the steering mounting bracket is thicker. I just didn't think 1/2 inch was enough for the throttle, steering, and grab rails. I wanted to build it up so the bracket is solidly mounted and the three bolts are secure.

Here's a shot of the underside of the console where the steering bolts through -the doughnut is another layer of ply (come to think of it, this about 1.5" thick, total)

The Teleflex bracket fits from the front and bolts through this assembly - washers, locknuts, done. Loose steering drives me up a wall.

Damn, I just want to make the CSC shindig for 2009 at this rate...

[strick]

Looks good Steve. The only thing that I would have done differently was put some toe space under that hatch cut out. I hate bumping my toes on stuff

strick

[warthog5]

I understand Steve. What you have done is fine and yes the steering wheel is a grab rail too.

As to the close holes on the mounting. That is perfectly aceseptable and is a standard machining practice to be the fastner diameter away from the edge.

On my boat the console is built with 3/8in Divenacell, but the area that the helm and control's are bolted to is 3/4in marine ply, for the reason's you listed above.

This is a pix where I modified the helm area after a change in the type control's was made.
This are is 3/4in marine ply.

[squidrig]

Very sweet looking.

Good idea not putting a head in there. That way you'll never have to pump out. RonZ would be proud Mr. Brown Eel.

[Lenny]

Oh that would look great in my boat

[stevebrownell]

That one was the prototype, you don't really want it.....

Of course, I have some electrical work that needs attention.