BronXpedition Center Console - Ford Bronco Forum
 21Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 51 (permalink) Old 01-04-2016, 12:02 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
BronXpedition Center Console

In the 10 plus years I've owned my Bronco, I've broken 2 shift tubes and 1 shift lever.... dunno why, don't think I'm particularly hard them..but so it is. Ever since I installed my 2000 Expy center console, I've had it in the back of my mind to convert to a floor, or console shifter. Ebay is a beautiful thing, or awful thing, depending how you look at it. I placed a bid, what I thought was a rediculously low bid, on this 2010 Expedition shifter.

image.jpg
Then, of course....forgot about it. It caught my eye because it was totally black, and the shift lever grips were hard black rubber, with checkering...like pistol grips. Exactly what I wanted. So, a few days later I get an email from eBay. Oh yeah...the shifter!....$70 incl. shipping...ok...guess I'm gonna do a floor shifter mod.

Hat tip to our beloved mod Bikerpepe for editing and moving this thread for me.

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-04-2016 at 01:24 AM.
RicoBronco is online now  
Sponsored Links
Advertisement
 
post #2 of 51 (permalink) Old 01-04-2016, 12:22 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Here's a closeup of those grips, pretty cool, huh?

image-4.jpg
One of the first things that I noticed, was this unit was wayyyyyyy too damn tall, and was gonna need to be cut down.

image-5.jpg
Kinda figured that would need to happen. After some consideration, I decided to stick it right in the middle of the big center pocket of the console. I've never really had a use for this big trough, and frankly, it aided in my decision to do this.

IMG_20150201_133904804_HDR.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-04-2016 at 01:26 AM.
RicoBronco is online now  
post #3 of 51 (permalink) Old 01-04-2016, 01:01 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
I say 'after some consideration', because a few things were factors in the placement of the shifter. Things like... Reach, Interference with other functions...Erogonimics in general. I didn't want to do this just for the sake of doin it, If there isn't an Improvement, whether it's performance or just personal preference (and thats a pretty broad spectrum) then why do it? I thought about placing the shifter further back towards the cup holders, and fitting in a few gauges between the climate control and shifter, but it was just too damn tight, though I wouldn't be suprised if the position changes before I start fiberglassing.
I won't bore you with step by steps, but here are a few pics of the process. The wood I used is called Appleply. It's a 12 layer hardwood plywood used for many applications. It's very strong, and accepts fasteners well. If I were using much more structural material, I'd probably use aluminum, but the work here is minimal, this amount won't add too much weight. And, I'm a carpenter, so wood is the medium I am most comfortable with.


image.jpg


image-6.jpg


image-7.jpg


image-8.jpg


image-9.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 02:26 PM.
RicoBronco is online now  
Sponsored Links
Advertisement
 
post #4 of 51 (permalink) Old 01-04-2016, 01:28 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
The 'tower' of the shifter, provided some nice areas to glue and screw some small blocks of Appleply for backing. One of the things I like about the appleply is it doesn't split or crack and works well for small pieces.
A few pics of the center console, hollowed out.

image-19.jpg


image-13.jpg


image-12.jpg

And how the shifter is fastened.

image-27.jpg


image-15.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-05-2016 at 11:49 AM.
RicoBronco is online now  
post #5 of 51 (permalink) Old 01-05-2016, 03:37 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Well, I decided to reposition the shifter. Moved it down and back. Much better, more comfortable to reach, and frees up some space to add auxiliary switches.

IMG_20160105_114736733-1.jpg

IMG_20160105_114745768-1.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-05-2016 at 06:29 PM.
RicoBronco is online now  
post #6 of 51 (permalink) Old 01-20-2016, 01:08 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Hey! I've made a bit of progress over the last few days. Everything is hooked up now, shift cable and electrical. Here's the pile of left-overs.

14532669180911.jpg

Getting the shift cable unhooked from the column was a lil tight, but hooking it up to the floor shifter was about the most aggravating thing so far. Ended up cutting out the plastic cross brace, (wasn't needed after the new bracing i added) That helped a lot, but getting the end of the cable on the stud was a PITA. Also had to shave down the little saddle that the shift cable sits in. Once on, it shifted nice and smooth, no adjusting was needed.

14532680229562.jpg


14532680355713.jpg


14532680498054.jpg
Made a ring for around the base of the shifter to provide a nice flat, level surface for the fiberglass work, it won't be there when I'm finished.


14532679782640.jpg


14532679486629.jpg


14532678785578.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 02:15 PM. Reason: larger pics
RicoBronco is online now  
post #7 of 51 (permalink) Old 01-20-2016, 01:29 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Since I'm losing my shifter, I'll need to relocate the overdrive-off light. There is a button located on the new shifter, but no indicator light. Keeping in mind my commitment to making this mod look OEM, I decided to put it in the now empty PRND12 indicator window inside the instrument cluster.

Started by removing the window from the shift nob. Then rounded the corners to match, using the window pocket as a gauge.

14532669597862.jpg


14532669750733.jpg


14532669930634.jpg


14532670741596.jpg

Attached Images
File Type: jpg 14532679968431.jpg (53.9 KB, 269 views)
File Type: jpg 14532670891997.jpg (49.9 KB, 1318 views)

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 02:18 PM. Reason: larger pics
RicoBronco is online now  
post #8 of 51 (permalink) Old 01-20-2016, 01:42 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
When I was at the junkyard, there was a 95 f150 there with a 5 speed, they don't have the PNRD21 shift indicator in the instrument cluster.so I snagged the blacked out window to mount the o.d. off light in. Also scored the steering column cover.

14532666598980.jpg


14532667055071.jpg


14532667229202.jpg


14532667651924.jpg


14532667849495.jpg


14532667982136.jpg


14532668160167.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 02:21 PM. Reason: larger pics
RicoBronco is online now  
post #9 of 51 (permalink) Old 01-20-2016, 01:50 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Cleaning up the cut with a dremel. A really useful tool for this project.

14532668389538.jpg


14532668594429.jpg


14532668719770.jpg

Ill use the light from the button as well. All the electrical went pretty easy. The brake interlock switch works. I didn't use the key interlock circuit. I took the illumination power from the abandon ashtray, its on a dimmer to, so the PRND21lights dim with the rest of the dash.
More to come.
miodynskia likes this.

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 02:23 PM. Reason: larger pics
RicoBronco is online now  
post #10 of 51 (permalink) Old 01-20-2016, 03:24 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
I had to crush the old shifter knob in the vise, and those tiny pins are a pain to get out of the connector, but managed to get the entire harness out of the shifter in one piece.

14533199456430.jpg

Drilled a hole for the wires, only need two, but I'll just leave the third and remove the pin from the Bronco side of the connector.

14533199581071.jpg


14533199807682.jpg

Tight fit, but no bigger than the other unit. I'll glue in the female connector...or now bulb base. That way if the bulb ever goes out, it can just be unplugged and replaced. The button doesn't work because its jumped at the connection.

14533199958663.jpg


14533200661604.jpg

Just taped up for now, need to make sure it fits and works.

14533200853185.jpg
Darth_ted_82 likes this.

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 03:45 PM. Reason: larger pics
RicoBronco is online now  
post #11 of 51 (permalink) Old 01-20-2016, 03:28 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
She works . Now I've gotta unwind it all to solder the connections. ..then, on to the fiberglass work on the top trim bezel.

14533200973196.jpg


14533201275837.jpg
Darth_ted_82 likes this.

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 01-20-2016 at 03:46 PM. Reason: larger pics
RicoBronco is online now  
post #12 of 51 (permalink) Old 02-17-2016, 11:22 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
It's a good feeling to have all the electrical finished and done right. Also have the manual steering column cover installed. It has a small hole for the key release lever, which I do not have, and probably will not use. But that hole is gonna bug the hell outta me, so I'll deal with it later.

14541264324951.jpg
Thought I might save some fab work by picking up another cup holder trim piece from the junkyard. $3 at the junkyard is well worth it, don't tell the boys on eBay that charge $50 for them. That window is for either climate control knobs, or a storage pocket. I'm using for Auxiliary light switches. If you look closely you can see that these were built out of square, to fit the contour of the Expedition dash. I'll have to deal with that.

14540830411621.jpg


14540880445200.jpg
After some hacking and cutting and more hacking and cutting, I got it where I wanted it. Hot glued some sugar pine sticks in for supports. I wanted the forward portion of the frame tipped up a bit to blend with the dash, and so the switches won't be lying flat, they'll be more square to your operating level, if you know what I mean.

14540880603891.jpg


14540831387734.jpg


14540831712016.jpg


14540831525535.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:26 AM.
RicoBronco is online now  
post #13 of 51 (permalink) Old 02-17-2016, 11:31 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Had some pink foam lying around, figured it would provide a nice shapeable backing to stretch some fabric around.


14540832218668.jpg


14540832358369.jpg


14540832476800.jpg


14540832615031.jpg


14540832854052.jpg


14540833092533.jpg


14540833474934.jpg
Darth_ted_82 likes this.

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:29 AM.
RicoBronco is online now  
post #14 of 51 (permalink) Old 02-17-2016, 11:55 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Here's the switches I'll be using, its a Ford oem fog light switch. I find them in first generation Explorer limited editions, and I guess they were in some other obs Fords. They have the same green back lighting as my dash, so they should go well in my effort to make this mod look oem.I can fit 5 perfectly.

14556732810530.jpg

I hot glued the piece to a pedestal to make for easier working. It'll pop right off as I will do this several times.

14542192449100.jpg

Added a small piece for backing, this will come off after the fiberglass has cured.

14542192562511.jpg


14542193116304.jpg

Here was mistake number 1. This is D815. I've used it on carpet jobs, for seams, or laminate repairs, etc. It's not that the glue didn't stick. This stuff sticks. It'll hold a whores ass in a church pew. But it's too heavy bodied for this application, as well as it sets up to quick. It worked, but it could have gone smoother.


14542193475165.jpg


14542193593566.jpg


14542193710877.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:32 AM.
RicoBronco is online now  
post #15 of 51 (permalink) Old 02-18-2016, 01:09 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
The fabric I used wasn't fleece. It was a thinner polyester/cotton blend, basically a T-shirt.

14542193929288.jpg


14542194027969.jpg


14542194506441.jpg

After some pulling and stretching and smoothing.

14542194888994.jpg

Mistake number 2. The adhesive melted the foam. Guess I should have brushed up on my chemistry.

14544744792881.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:34 AM.
RicoBronco is online now  
post #16 of 51 (permalink) Old 02-18-2016, 01:36 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
A little rough-up with 80 grit.

14557751094040.jpg

A little clean-up with alcohol.

14557751310261.jpg

First coat of resin.

14557751665272.jpg

Form block

14544744090770.jpg

Form block removed and another coat of resin.

14545654425030.jpg


14544748362532.jpg


14544746085467.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:38 AM.
RicoBronco is online now  
post #17 of 51 (permalink) Old 02-18-2016, 02:03 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Addressing mistake number 2, after a layer of fiberglass clothe.

14544745977646.jpg


14544748217041.jpg


Reinforcing the corners with matt.

14544748042639.jpg

I'll do 2 layers of matt on the top, it will get the most abuse.

14544748129400.jpg


14544745726424.jpg


14545290495630.jpg

A gauge block to check for square and pitch, I can use it as a guide for the dremel as well.

14545290722981.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:42 AM.
RicoBronco is online now  
post #18 of 51 (permalink) Old 02-18-2016, 02:20 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
See. Second layer, should be strong enough.

14545290882162.jpg

After a final coat of resin, and a lot more elbow grease.

14545654667642.jpg

Time to cut a hole. The mdf backing piece acts as a cutout template. I can just drill holes from the bottom, them connect the dots up on top.

14545654976513.jpg


14545655111114.jpg


14545655723268.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:44 AM.
RicoBronco is online now  
post #19 of 51 (permalink) Old 02-18-2016, 11:50 AM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Cutting out the MDF backing.

14545655276285.jpg


14546302522441.jpg


14546302436370.jpg

Much cleaner, and a little lighter.

14545655406026.jpg


14545655619107.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:47 AM.
RicoBronco is online now  
post #20 of 51 (permalink) Old 02-18-2016, 12:09 PM Thread Starter
Bronco Snob
 
RicoBronco's Avatar
 
Join Date: May 2012
Location: Spokane
Posts: 1,825
Bronco Info: 1992 XLT 351W E4OD 4" lift TRE flip 225 amp 3G Alt Saginaw P.S. BBK Headers Bassani Y....
iTrader: (1)
Garage
Time for a test fit, to see which areas need attention before I start the Bondo-glass.

14546306206819.jpg


14546305179558.jpg

I wanted to make sure it's close to the dash, but not touching. Don't want any squeeks or rattles. I want it to finish out about 1/16" away, then I'll line it with some 1/8" weather stripping so it compresses against the dash when the console is bolted down.

14546302762012.jpg

Here I made a sharper corner, I'll have to extend the bottom part of the console to meet the dash.

14546303765213.jpg


14546303941464.jpg


14546304357405.jpg

And here, I'll have to build it up a bit.

14546304774856.jpg

A society that puts equality before freedom will get neither. A society that puts freedom before equality will get a higher degree of both. - Milton Friedman -

Last edited by BikerPepe`; 02-21-2016 at 01:49 AM.
RicoBronco is online now  
Sponsored Links
Advertisement
 
Reply

  Ford Bronco Forum > Bronco Discussions > Technical Write Ups

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ford Bronco Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself. DO NOT USE Gmail.com accounts. If you only have a Gmail.com email please contact the administrator here

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome