Over the last two days I’ve spent some hours making and fitting the front side consoles from foam. I’m using 0.4″ divinycell R35. Plans say 0.35″ and R45. I have what I have.

After making the pieces they were quite bendy so I’ve hot glued some timber to the outsides for assembly. I spent some time fitting the tops into the sides. In reality this may all get trimmed back once the windows are in. For now its a very nice fit.

Pic 2 shows me checking for equal tops and bottoms with a mixing stick adjusted for the occasion. Its hard to see what is straight. This is pretty close with an equal gap throughout the cavity.

Pic 3 has the tops glued to the sides. I’m using Polyurethane glue rather than micro. Its cleaner and lighter and does the job properly. When its cured tomorrow, I’ll carefully take these out and give the insides one ply of BID. There is quite a bit to do on the armrests but I’m enjoying the process of thinking through these modifications and doing small jobs for a change.

I have a bunch of ideas for this area as this is where I put the organic computer and piloting mechanism as well as all the bionic systems for the build. This need a good housing so it maintains functionality.

A close fit to the seat

Gap checking tool

Pinned and glued tops to sides