Throttle Quadrant
I
bought a standard throttle quadrant from Aircraft Spruce that has the throttle
and mixture handles. Its body is about 2" wide including the bolt heads and
nuts. I wanted to hide all the bolts and nuts (of the quadrant) inside the
console, so, I know I have to carve into the foam right off the start if I want
to keep the center console the same width as the heat duct (the heat
duct is 2" wide including the 1/4" thick foam on both sides). It was suggested
in the plan that they should be removable for inspection and maintenance down
the road. To me, that means I have to have some kind of removable cover, so
that I can access the throttle quadrant as need arises.
I
marked the position of the quadrant on the console sides and Dremeled out the foam
holes where the bolts go. Note I was off a bit - that was not intentional 
.
I also embedded & floxed a couple T-nuts in the foam on
each side of the console for securing the quadrant body (note the t-nut posts butt against
the sides of the quadrant body). I used an aluminum strip (or a large washer) to
secure the quadrant in place. The strip on the other side of the console is
mounted in the opposite orientation, forming a 'X' configuration - keeping the
throttle quadrant from any rotational movements.
Once
I got the quadrant mounted, I decided to give it a trial fit. As always, Murphy
will come visit when you least expect it 
. I could not slide
the slots (on the console cover) over the control arms because the tip of the
arms are slightly bent (intentional). I either have to re-design/re-make the cover or
modify the control arms. Since I was thinking of replacing the two ball knobs
sometime down the road, this gave me the excuse to make the change at this time.
I removed the quadrant arms and traced them out on a 1/8" thick aluminum
sheet and cut them out with a band saw. Then I cleaned up the edges with an end
mill. I measured the hole locations and match
drilled them on my drill press. I re-assembled the quadrant and re-fit on top of
the console. Note my throttle quadrant is mounted onto the center console
without external bolts and nuts as shown (left).