Hobbies And Interests
Things You'll Need
Instructions
Planning
Gather all necessary measurements. This includes not only the console's dimensions, but also the dimensions of the steering column and any navigational instruments and other devices you plan to install in the console's dashboard.
Draft a 1-to-1 scale plan of the console's sides, front and back. Check against these drawings when cutting the parts.
Draft a 1-to-1-scale-plan of the console's dashboard. Include all panel cutouts for the steering column and instruments.
Transfer the drawings to the plywood sheet. Use the L-square, straight edge and protractor to make sure all angles are accurate and all lines are perfectly straight. Check all dimensions with the tape measure.
Cutting the Parts
Put on your safety goggles and steel-toed boots. Cut all parts on the table saw.
Set the table saw's blade to a 45-degree angle. Placing the parts' exteriors side onto the saw, re-cut all parts' side and top edges. Since the dashboard doesn't have a bottom touching the boat's deck, re-cut all of its edges.
Set the blade back to the original 90-degree angle. Cut four lengths of dimensional lumber that will make the console's foot. Two pieces needs to be 2 inches shorter than the console's with. The other two need to be 2 inches shorter than the console's sides.
Cut four 3-inch-lengths of dimensional lumber. These pieces will become angle braces.
Set the table saw's fence to a 45-degree angle. Angle off the corners of the piece going against the console's front so that you have an elongated trapezoid. Angle off one corner of each side piece. Use a push stick when cut the four angle braces to right triangles with a 3-inch-base.
Place the dashboard on the sawhorses. Drill a hole large inside each cutout enough for the jigsaw blade. Cut the panel cutouts with the jigsaw.
Assembling the Console
Place the console's four foot-pieces together, so that they form a rectangle. Use the L-square to ensure perfect right angles. Attach a Phillips head driving bit to the power drill. Attach the pieces by driving two 3-inch wood screws through each corner through the angled-off miter into the next foot piece.
Sand the angled-off edges of the console sides with your third-sheet sander. Use coarse-grit paper first, then medium-grit, then fine-grit. The sanded surfaces must be glass-smooth. Wipe them off with your shop rag.
Cover the console panel's sanded sides with glue. Leave the top edges alone. Place them together around the console-foot.
Wrap the strap clamps around the bottom and top. Slip cardboard squares between the console's corners and the straps. Tighten the clamps.
Drive 3-inch wood screws through the console's bottom into the foot at 4-inch-intervals. Let the glue dry completely. Remove the strap clamps.
Reinforce the console by driving 3-inch wood screws into the console's edges through the angled-off miters into the console's other side. Place the screws at 8-inch-intervals.
Sanding, Staining and Finishing
Sand the console and dashboard with the third-sheet sander. Start with coarse-grit paper, then medium-grit, then fine-grit. All surfaces must be glass-smooth.
Wipe the surfaces thoroughly with a shop rag. There should be no sawdust at all on any surface.
Apply a coat of stain with cheesecloth. When the stain is completely dry, gently sand it with fine grit paper. Wipe off all sawdust with a shop rag. Apply a second coat of stain.
Cover the stained surfaces with a coat of polyurethane wood finish when the stain is completely dry. Use smooth, downward strokes when you use the paintbrush. Let the wood finish dry completely.
Installing the Console
Place the console on the deck, over the steering column and instrument wiring. Fasten it to the deck by driving 3-inch wood screws through the foot-pieces into the deck.
Mount the navigational instruments to the dashboard according to the manufacturer's instructions. Attach the wiring according to the manufacturer's instructions.
Cover the console's remaining mitered edges with wood glue. Place the dashboard onto the console. Fasten it to the console with 3-inch wood screws, placing the screws around the dashboard's edges at 6-inch-intervals. Attach the steering wheel to the column according to the manufacturer's instructions.