I posted this in my project blog, but I know not a ton of people read that section, so I'm tossing it out here in case anyone is building their own anytime soon.

Project Center Console is shaping up to be nearly as complicated as my Intake Manifold project... There are 36 bolts and nuts that hold this thing together! Along with a bunch of custom aluminum plates for the joints to keep everything hidden, and countersinking the bolts, this has taken a lot of time.

I wouldn't recommend this method unless you're crazy like I am, have a bunch of free time, or just really hate exposed screws in upholstery. I like the stock look of the '02 console, but I've always hated the screws just sitting there on the side of it.

I did work car stereo install for several years, so I know my way around MDF pretty well. For anyone looking to do this, here are a few tips:

Screw together 2 pieces of MDF and cut your sideboards as one piece. This will make it much easier to make them as identical as possible.



If you don't have a router (like me) and you want rounded edges on your console, angle your jigsaw and cut along a 45 degree angle first.



The follow up with a DA, grinder, sander or the like, and finish with rough sandpaper:



Test fit constantly. I'm not going to have any exposed screws on my console so I need to make sure the fit is perfect. If you want to screw yours together for the time being, wood putty will hide the holes very well, especially once covered in vinyl.



The "faceplate" was the hardest piece to test fit. this would change size depending on how the bottom piece in the shot above was angled



Finally, when you've got it all set, spray the joints with primer or other fast-drying paint. Don't use a brush because you don't want to knock anything out of alignment...



...this way, when you take everything apart, you have nice clean lines where everything should go:



This is where things start to get a little... carried away. If you never intent on taking your console apart, then sinking screws into the MDF will be fine. I worry about stripping out the holes in the MDF after a while though, and as I said before, I don't like exposed bolts. My solution was to build the entire thing with L-brackets and countersunk bolts.

One of the harder pieces: the faceplate



An example of the countersinking. Bolts are inserted here and then covered in epoxy to hold tight. The holes are then covered in wood putty:



Some of the more complicated brackets that hold this all together. This is all so I don't have exposed screws!



There are over thirty bolts keeping this all in one piece:




Those are just some spare gauges I has laying around for a test fit. I'll be putting voltage, amperage, and WB o2 gauges in there once its all wrapped up. The whole thing is being wrapped in black vinyl, once I get the final sanding finished around all the wood putty holes. My MSII ECU is also mounted to the inside passenger side panel, with an extension line running up to the glovebox for tuning.

If you don't intend on going the crazy route I did, this is a fairly simple project that can be done in an afternoon or two. Like most things though, I tend to go a little overboard...
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