Any interest in reproduction console lid plastic?

[1998rollover]

If there's enough interest in it, I can make a mold from the polycarbonate part of the console lid, the yellow or green upper part with the screw posts that break, and cast new ones in urethane resin.

Just took one apart on an 02 Sport Trac and will have to somehow repair most of the screw posts. It's the same piece as the 2001 and back Explorer and Mountaineer.

Price? Depends on if there's any demand and how much demand.

The best way for me to make the mold will be to start with a pristine original, never assembled part without any cracks or staple holes. Otherwise I'll have to build up broken posts to have them shaped to make the mold.

 

[Texas_XLT]

Did you ever proceed with these covers?

 

[koda2000]

Brand new lids are still available on eBay (complete and covered). They're a bit expensive and it's not only the screw posts on the upper part that break. The bottoms usually develop cracks or worse. I can't see anyone being able to make the upper part inexpensively enough to make it worth while or cost effective. Plus IDK if the resin would hold up to staples. Often you can find decent used/recovered ones on eBay and for less money than the brand new ones. I've covered a number of them with good success, but the screw holes are certainly the weakest part.

 

[1998rollover]

I made one for a 2002 Sport Trac and it worked well. The resin I used is extremely strong and also takes screws well into holes without breaking. Crazy that Ford used such a brittle plastic for these. If I'd been involved in designing that part, I'd have told the engineers to go find a different plastic that wouldn't crack when staples and screws are driven into it.

 

[J_C]

Well, if it's really polycarbonate, which I doubt, it would probably be more durable than urethane in this application, except if directly exposed to sunlight/UV and I mean the plastic, not the cover vinyl (or leather?).

IMO it's more likely ABS or another formulation instead of polycarb. Either way my main point is, you're talking about plastic that has aged, possibly outside in temperature extremes, for over a dozen years. FYI polycarb does not crack very easily at all. Remember it's the stuff bullet proof glass is made out of.

Staples though, may not be entirely necessary. There's old school stitching or epoxy could attach the cover, would just need done in portions and clamped till it set since you wouldn't have a custom form to hold it all in place at once to set. Well, you might be the one person who could since you're adept at making molds.