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Old 30 August 2018, 20:55   #1
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Country: USA
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New Console Build

Building a new Jockey Console.
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Old 30 August 2018, 20:57   #2
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Adding shape

adding a little more detail
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Old 30 August 2018, 21:00   #3
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And the work goes on

Still more detail, making a real mess with this foam.
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Old 30 August 2018, 21:05   #4
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Now for the fun part

Cover this baby up! fell short on the photos of this step, to much frustration. Not the fun part of a build.
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Old 31 August 2018, 06:27   #5
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hi Ryan can you give a bit more detail is it closed cell foam your using and what are you rounding off with tool wise interesting project
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Old 31 August 2018, 10:13   #6
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I build the spine of the mold using cosa board for stiffness. I then glue 4lb foam in layers to build up the profile. I use a hand rasp, sandpaper a shaper and orbital sander to shape the plug. I also use a standard 3/4 round over router bit for my outside radiuses for consistency. When shaping i mark all the lines on both sides before i start as far as where the profile changes. Then i shape one side and make cardboard templates of the transitions so i can match the best I can on the other side. I fill all low spots with P-77 then i shoot it with duratech and sand, polish, wax. then PVA, GEL, mat stiffeners then mat and thats the process in f fwd.

Hope that helps.
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Old 31 August 2018, 10:17   #7
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Final phase

Finished coating, sanding making and mold making first part out of the mold
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Old 31 August 2018, 10:21   #8
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Frame Work

Now we need something to sit on. I designed an aluminum seat frame and had a friend water jet and bend it for me. We added a ss stud to the frame to stop the bolt from eating the aluminum. We drill a hole the width of the console and install a threaded aluminum axle to allow for the secure attachment of the frame.
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Old 31 August 2018, 16:03   #9
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Building the Seat Cushion Frame

We made the frame for the seat using 1/2 PVC board. made templates out of cardboard then cut and bent to produce the frame to send to upholstery.
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Old 31 August 2018, 16:08   #10
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All done!

I know this was a fast fwd thread sorry. I kept meaning to share and always got busy.

Also a special detail this is carbon fiber construction.
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Old 31 August 2018, 16:36   #11
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All done and ready to go out the door.

This is a final build and boat is headed out.
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Old 31 August 2018, 17:20   #12
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Well impressed great job
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Old 01 September 2018, 01:57   #13
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that looks good why did you not make the seat a suspension seat wouldn't take a lot
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Old 01 September 2018, 13:50   #14
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Working on it.

I'm working on it. this design was always for suspension, but the client did not want extra weight. the tender is made of carbon fiber.
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Old 01 September 2018, 23:20   #15
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wow very nice
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Old 27 September 2018, 19:24   #16
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Shock mitigating?
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