Glovebox fabrication

The glovebox, like the fresh air vents, has been a 'side project’ that has taken a lot of effort and has pushed my fabrication skills.  There are several builders in the F5 forum that have made very nice glove boxes and I’ve adapted their techniques and processes to my skill level and tools.  Because I only have relatively modest metal working tools, I used wood for box parts rather than metal sheeting (except for the basic shape).  More photos are here.

The box itself is made of aluminum coated with fiberglass.  However, I made the form for creating the basic box shape using 3/4” wood.  I wanted the box to be about 3” deep to fill up most of the behind-the-panel space.

The Al flashing (from Home Depot) was wrapped around the form and then the overlapping ends were glued in place using JB Weld.  

I used two wood screws to hold the ends together while the glue dried and put some wax paper between the Al and wood so that the form could be released.

I needed a way to attach the glove box to the dash so I made an attachment ‘ring’ out of 1/8”, high quality plywood.  As can be seen in the above photo. the Al flashing extends 3/4” beyond the wooden form.  The ring was positioned at the edge of the form so that the 3/4” of flashing could be folded back against the ring (below).  

This allows the box to be fastened to the back of the dash with the ring pulling the box toward the dash with the flashing being between the ring and the dash:

The end piece for the box was also made of 1/8” plywood and the end piece, ring and Al flashing were fiberglassed for rigidity:

The shape of the box was constrained in part by my ability to cut a hole in the dash.  To solve that problem I basically used the hole cutter for the gauges to define the end curves

and then cut between the two holes I created using pneumatic metal shear with some filing to make the edges straight.  In the test fitting below, the box is attached to the dash using bolts through the attachment ring.  Eventually, I’ll use screws that are countersunk and flush with the outer face of the dash.

The glove box door is also made of 1.8” plywood.  Shown below is the door being test fitted against the glove box opening.  The glove box will have padding and the vinyl covering so the door dimensions need to take that into account.  The dash face will also have padding and vinyl of the same thickness.