Last week we designed and made a 1972 BMW 2002 Center Console for one of our customers. Our customer brought his 2002 in over a year ago to do some restoration work. This was one of the items on his list that he wanted, among many other items.
There are a few companies online that sell center console kits. However, most of them have 52mm gauge pods built in, or you have to buy multiple kits to get what you want. In this instance we designed to draft up our concept in Fusion 360 CAD and make it ourselves. We drafted up the basic profile of the sides. Then we 3d printed the sides, and test fit to make sure the fit was proper under the dash. After that we 3d printed drafts of the center sections. The first prints were about 15mm narrow on either side and did not allow us to put it under the dash.
After knowing the exact size, we changed a few features on the design. For example, we changed the cup holders from swuare to round. We did not like they was they looked and they did work correctly on the first draft. After finalizing our design, we started printing our final prints. We ended up using about 3kg or around 6.6lbs of filament with the drafts and final production pieces. Don’t mind the red size panel, I ran out of black filament. It will get covered up later, so I doesn’t really matter too much.
After the final parts were finished printing, we installed brass wood inserts into the plastic. We use a torch to get the brass inserts hot, then screwed them in. If we didn’t get them hot first, the PETG plastic we use to print this would have cracked. PETG is a very strong plastic that is weather and UV safe. Similar to ABS, but easier to print than ABS but much stronger. Most people use PLA on there 3d printers. PLA breaks down overtime, is not UV, and will absorb moisture. PETG is more difficult to print than PLS and it requires a hotter temperature to extrude from the nozzle. We use special diamond tip nozzles and had to customize and modify our 3d printer. We do this in order for us get better quality prints off our printer.
Once the brass insert were installed we dry fit the parts together to make sure everything fit properly. Once we verified the fitment, we started wrapping the parts with marine grade vinyl upholstery . This material looks exactly like leather, and gives the piece a more vintage look and feel.
Once we installed all of the faux leather (pleather) on this BMW 2002 Center Console, we installed felt on the circumference of the cup holder inserts and rear tray. We also put felt around the outside of the cup holders and tray inserts to make sure there were no rattles. (not in photos) This also help press fit them into place, although, they can still be removed for cleaning purposes.
One other thing we noticed after the dry fit, the hazard button harness does not fit. We are also 3d printing a connector so we can elongate the harness and allow us to plug in the switch in the lower location. In hind sight, we should have put the switch up top, however we did not want the radio to be and knuckle height when shifting the BMW. I personally have owned vintage vehicles that had the radio directly infront of the shifter and always found myself touching the buttons when shifting into reverse, first, third and fifth gears. So having the button in this location, recessed, was probable a better decision.
For more information on how to get your European classic car in the shop for some service, maintenance or custom work, contact us at 425-254-0627. You can also schedule an appointment or receive a quote by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and at the westside of the Paccar / Kenworth plant.
