How I made the fiberglass console.....
 


 

    I did it all my self.  I was in school so it took me a while, plus I had to learn how to lay fiberglass without any instructions.  Here's what I used:
 
    -Some aluminum screen or chicken wire for the template/frame.
    -newspaper for paper mache
    -two cans of fiberglass resin
    -some fiberglass mesh
    -can of plastic body filler
    -sandpaper, lots, different grits
    -wrinkle finsh paint for the final textured look
    -rubber gloves and lots of em.

    First I used ordinary aluminum window screen to make a template.  It worked but I
think something stiffer like chicken wire would have worked better.  Be careful not to scratch up the existing interior too much.  Cut, fold, do whatever to the screen to get it in the basic shape that you want your console to be.  Take the time and make all of the nice detatils now, because it will be harder later.

    Next lay paper mache on the inside of the template, and get it as flat as you can now, makes it easier later.  Don't paper mache both sides, I made this mistake. What happens is when you lay fiberglass over the paper mache, you end having 2 layers of fiberglass with a screen in between with out them being connected with fiberglass.  I'd recommend laying paper mache on the inside so when you lay the fiberglass the screen hardens in the resin thus becoming an integral part of the console making is stronger in the process.

    Now start with layers of resin and fiberglass mesh.  I first laid some layers of just resin to level it out then did layers of resin and fiberglass followed by a final layer of just resin.  Note it takes the fiberglass a couple of hours to dry, and longer depending on the thickness of your layers.  Here's a tip, try to get the resin as smooth as possible when you poor it and before it starts hardening.  If you try smoothing it after it starts getting sticky (stickier than normal) all you will doo is leave ridges that will require more sanding later.  Again I learned this the hard way.

    I used layers of bondo to get the final smoothness.  For one hardened fiberglass is a b@$ch to sand, try sanding your windshield!!!  The plastic body filler (bondo) dries fast and is very very easy to shape and sand.  It allowed me to smooth the corners and  transitions.

Last paint.  I found some wrinkle paint at Autozone that left the console with a texture that very closely resembles the factory plastic pieces.

Hope this helps.  Any more questions feel free to email me.

As for future tries, not until I have the time and money, maybe this spring/summer when I'm co-oping and not in school. We'll just have to see.  You'll at least be starting off with more info than I had.

Good luck.
PS f-glass resin is nasty when it gets on you!!!!