So I am just going to do a brief informative writeup on my take on the cupholder mod. I did not want to relocate the rear window switch so I am going to share with you guys how you can plastic weld parts from your old console into a switch panel and attach it to the new console. Subject here is a '97 SR-5 5 speed E-locker but this applies to most if not all 96-98 models. Im not going into detail on the whole mod as it has been covered before. I am just concentrating on the plastic welding and placement of the panel in the new console.
[/URL]
[/URL]
Parts list required to make this fairly simple.
99-02 Console (best to find one complete as the lids are different on the newer ones with a better metal hinge and a second tray that attaches to the cover. You can make your lid work but it doesn't latch properly.
E-brake handle from same years truck
First step is to remove old console. You don't need to remove the seats for this as it is just two screws up front and two bolts inside the console.
remove old e-brake handle, don't forget to chalk your wheels if you have a 5-speed as it is possible to bump the shifter out of gear. Remove cable retainer tab on the bottom of the newer style brake handle as it interferes with movement. Remove and bend z-bracket (this may take a couple test fit trials to get right).
Install new console. Now comes the fun part.
Cut your old switch panels from the old console I used a measure of .5 inch from the top and bottom of the upper and lower surface of the switches. I have done this two ways once with a dremel and this time with a fine toothed wood saw. I think the wood saw was easier and less messy. It also provided straighter lines.
Make your cuts as straight as you can as you will be sanding them down flat to get a good mating line. Sand the two halves flat by whatever means you can make work. I used a DA pneumatic sander but sandpaper and a good flat tabletop will work just as good.
Once you are happy with the way the two halves meet turn them over line them up and tack weld them together. I like the cheap plastic welder from Harbor Freight Its cheap and works just fine. Use the pieces left over from the cut console switch panes as welding rod as the plastic is much better than what comes with the welder. Finish by stitch welding the two halves together. Don't ever get the plastic pieces to hot. If you have never plastic welded before use the old console and practice until you get the hang of it. It is real easy one you figure out the melting point.
Next figure out the placement of the panel in the hole (you will need to remove the storage compartment if you haven't done this yet) It is a tight fit to get all four of them in there but there is just enough room to make it work.
Tack weld in two places being careful here. I burned through in a small spot and it is visible but not bad at all. Check your alignment. If your happy start welding all the way around.
Only one more step and that is to adjust the console to accept the cupholder with new switches and you need to make a cut right here.
I am going to add some seat warmers in the top two switch holes when I replace the leather with Katzkin leather.
I hope this will help some of y'all out there who want to maintain the dash in the 96-98.
6 cupholders in all!! Awesome!
Linear Mode
