Re: steering console
my son and i converted a 15ft Tuffy to side console this summer. we started by looking at the commercially available side consoles and they were too expensive. then we did the ebay thing trying to find a used one-no luck. so we were like you and decided to build one. fortunately for us there is a cabelas near us. we went and found a couple of boats that were very similar in size and started measuring and taking pictures. then using the measurements we built a cardboard console. changed the shape several times until it looked and felt right. then using the measurements from our prototype we copied it using 3/8" exterior plywood. once we had it glued (PL adhesive)and screwed together we took the belt sander and rounded all the corners and edges. then we used Bondo to fill all the cracks and screw holes to give a smooth surface. then we fiberglassed the entire console putting 2 layers of cloth on the edges. sanded that smooth and brushed on another coat of resin and sanded that smoooth. we also resined the inside just for extra waterproofing. then we cut the holes for the instuments and helm and resined the edges to seal them. then we primed it and looked for the imperfections. a little more resin and sanding and we ended up with a console that looked like it was molded fiberglass to match the boat. it actually was much easier to make one than we thought it was going to be. most of the time was in waiting for fiberglass to dry to go onto the next step. we sat on it when were done as our strength test and it passed with flying colors. actual construction time (if you don't count the time drinking beer talking about what we were going to build) was probably no more that 7 or 8 hours. and of course if you don't count the time going to cabelas because that is always a 2 hour trip by the time you look at all the stuff you don't need or can't afford. i can't give you a actual cost because we made it out of all leftover stuff from other projects. but if i were to guess i would say about $40 if you had to buy everything new. (plywood, resin. cloth,screws,glue)
