So I finally got the center console for my C5 vette that ive been waiting on, this specific part is the reason for my interest in composites. A real carbon fiber version retails for 4 digits, and I dont want to fall into the hydro dipping vette guy stereotype. I consider myself a semi-professional DIY'er, so I figured why not learn something new. I've watch some videos on youtube but this center console is extremely complex (and maybe not the best first project)

Here is the console.




The biggest problem that I can see is how create the whole piece with the inserts and tabs.

Im guessing I could create the cup holder and the storage area/ cigarette lighter bits separate and press them together with some 2 part adhesive.

My question to ya'll then is, whats the beset way to start with mould? I'm not sure what material I would use. The biggest thing about this project is that I would like the keep the integrity of the original part, it wasn't cheap and this specific one isn't made anymore.

Here are a few more pictures for clarity.

HI,

You would certainly want to remove the cup holder and storage area flaps as a separate project.  Perhaps if the lighter storage box can actually be removed, that would simplify things a lot.

Clips on the back are normally done afterwards and bonded into place.  You may need a bit of redesign of how you fix it to the car.

Other than that, you need to block all the holes and then its relatively conventional moulding process.  Just double check the sides don't mean the part would mechanically lock into a one part mould.  If it looks like it will, you may need to go to a 2 piece mould or more.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Silicone moulds can't be used for making carbon parts, at least not ones with any degree of accuracy required. Composite parts need rigid moulds.

You could do the mounting clips with silicone moulds, and potentially the storage and cup holder areas as well. If you made silicone moulds of these parts and then cast them with a rigid polyurethane, you could then bond them to the completed carbon surround.

This sort of thing does need to be redesigned somewhat, you can't make it in the same way as OEM.

After digging through some info and videos, I think I may try to treat this piece in the same way as a hood to try and retain the general shape of the storage area and the large brackets near the end of the piece. After mega-zooming in on the pictures of a company that makes many carbon fiber parts for corvettes, I see that they just skin the majority of their parts. I think that if i can pull off a full carbon part, I should have a selling point over them. Assuming I can make a decent part.