2003 console in obs install (pic heavy)

[DallasTahoe]

After going through hundreds of posts on multiple Chevy/gmc forums I found little to no info, so I guess I'll do a full write up on how I'm doing mine so here goes!
Here's what I'm starting with, a console from an 03 Avalanche, now none of the Bose stuff is staying, it and the a/c vent tubes are coming out, not so much because I'm not going to use it but it makes it lighter when test fitting.


First off you'll need to test fit before you do anything so you can see if you want to even tackle this install because of the fabrication involved



Problem with this particular console is that it's not a direct bolt in, there is some work to be done.
First thing I did was trim the upper left corner to get the console to fit tighter and have less gap between it and the dash panel, STOP!!!! This is what I did but in hindsight I would not have given the chance again. I wanted the least amount of gaps all the way around
You'll need to check the fit vertically on both sides, I actually trimmed the side panels down to allow a better fit


The blue tape in the pic is actually there to mark a cut line, yes a cut line into the dash panel. Again this is how I did it, those dash pieces aren't hard to find or expensive. Here's how it looks after its cut


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[DallasTahoe]

When you cut this panel the gap only needs to be about 2 1/2-3 inches, if you do it like I did you keep all your mounting locations. Time to test fit again
Als cut the two black boxes off of the back side of the console

Passenger side still has a considerable gap
Using cardboard I made a template for a filler piece

Using the template I made a panel from a sheet of 1/8in fiberglass panel
I epoxied it in and used rivets to hold it, I've used epoxy on this kind of plastic before and it doesn't always work so great, hence the rivets which can always be removed later. For the filler piece that goes on the top that takes some time, lots of shaping on my drill press with a sanding drum attachment
Once you get it fit use the scrap plastic from trimming the bottom of the console panels and superglue them in to hold it in place. Once that's done do some smoothing and sanding then another test fit
I'll put more on this once I get off work to tackle the fiberglassing


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[Tonyrodz]

Damn good fabbing!!

 

[DallasTahoe]

Damn good fabbing!!

Hey thanks man! It's not done yet once I get home from work I'll be doing some Glassing on it to get everything as tight as I can


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[Tonyrodz]

I don't have an obs but I appreciate good fabbing skills. Looks good!

 

[DallasTahoe]

Ok so now that the epoxy has dried I can fit my fill piece for the fiberglass panels. I went to the junkyard and took a flat piece from another console and cut it to fit and trimmed it in and epoxied it to the fiberglass panels. I also drilled out the rivets and filled the holes with epoxy. If you wait until the epoxy is kind of gummy you can cut off the excess and touch it and knead it with your fingers on the panel and it gives it a similar texture to the original panels and once painted you can't really see the patches or holes


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[Tonyrodz]

Looks like it's coming along nicely.

 

[DallasTahoe]

Now it's time to fit the mounting bracket. The original rear bracket can be used, just take it off and reverse it and put about a 3/4in spacer underneath and screw the old bracket to the new one. For the front part you can use the existing mounting hole


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[DallasTahoe]

By the way way don't laugh at the nasty carpet, that's going to get redone real soon


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[Tonyrodz]

I can't wait to see what it's going to look like once it's done. Painting it the same light gray as the rest of your interior?