The instrument panel I purchased had an AM/FM radio and CD player originally installed in the lower right corner. Since I opted not to purchase this particular component, the panel was left with a mounting hole that was approximately 6.25" x 2". I considered mounting a cover plate in the panel but opted instead to fabricate a small glove box. In hindsight I should have just bought the original radio or installed the cover plate.
In any event, I set about making a metal box of to fit the opening in the panel. I made cardboard templates first to get the sizing correct and experiment with how best to form the various pieces and flanges. I ended up fabricating a three piece box (bottom and sides with two assembly tabs for the back, a top panel with two tabs, and a back panel with two tabs).
To date, I have used a bench vise and some angle aluminum to make required bends in various metal components. This box required quite a few bends so I decided to purchase a small 18" metal brake from Harbor Freight. It made the work go a little faster but I am not sure it was worth the $32 cost. I will have to use it a few more times to fully justify the expense though small. By the way, you can see in the photos below I used mostly blind rivets to speed the effort since they are mostly hidden.
