Ok, finally got to my project this weekend. I ended up making it out of a piece of panelam I had laying around the shop where I work. Panelam is basically a 3/4" piece of plywood that has a vinyl overlay on one side. The piece I had happened to work out perfectly cause it had black edge banding around the perimter of it. Steps taken were as follows:
1. Using a piece of carboard, trace the contour of the seat back.
2. Cut two pieces of panelam to be 12" long by 8" high. Trim the two pieces so that they are 8" high at one side and 7" high at the other (creating a slop that starts at the back and goes down 1" towards the dashboard which will help offset the slant of the seat and give you a little room while shifting).
3. Using cardboard template, cut the backs of the two pieces to match the contour of the seat back.
4. Cut two pieces of panelam to create the front and back horizontal pieces.
5. Cut one piece of panelam to create the lid. I cut mine 1/2" larger in both length and width to create a little lip to grab when opening the lid.
6. Using carpet (mine was vertically ribbed wall carpet from Shaw), carpet the sides of the console you desire. For me, I carpeted what was going to be the inside of the three pieces and the outside of the lid. I wanted the outside of the lid carpeted so that it would create a softer surface for my elbow while driving. I used contact cement to adhere the carpet to the panelam. Be careful to mark off the places on each piece where they will join to the adjacent piece. This spot on each board must be left free of carpet. to creat a clean joint and good bonding surface.
7. Join the four sides forming the console. I started off using construction adhesive and then kept them together using finish nails. The construction adhesive was not enough to hold it together. Looking back, a better option may have been using screws with finish washers.
8. Mount lid to box. I used two small hinges that I found at Home Depot
for a couple bucks. They mount to the side of the console so that when opening the console, the lid opens up away from you towards the passenger.
9. (Optional) Mount magnetic latch to inside of console and bottom of lid. I did this and am debating if it's worth it. The lid seems heavy enough and a little tight to open..
10. Cut a small piece of 3/16" masonite to the width of the console but about 8" longer than the depth of the console. Nail / Screw the masonite to the bottom of the console. If desired, prior to nailing / screwing the masonite to the bottom of the console, test fit the masonite and using a pencil mark out where the inside sqaure of the bottom of the console lands on the masonite. Glue and carpet in this marked out square (creating a fully carpeted inside of box if that's what you like - I did).
11. Allow everything to sit overnight to let the adhesives set and dry.
12. Install console in truck by sliding the extra 8" of masonit between the seat back and seat bottom and pushing it all the way back to sit flush with the seat back. The masonite prevents the console from sliding left to right and front to back.
If anyone wants to try it and has any questions, feel free to contact me.