With the gap defined, the panel itself was designed first.

Before solving mounting, the interface had to be structurally sound. The panel would serve as the load-bearing surface for mounted equipment. Its geometry, material, and slot pattern were resolved prior to developing the attachment method.

Size & Scope

The panel was designed as a 6″ × 6″ module.

The footprint was intentional. Large enough to carry meaningful equipment. Small enough to remain proportionate to the center console pocket area.

Oversizing would introduce interference and unnecessary leverage against the mounting surface. Undersizing would limit practical use.

Six by six provided usable surface area without overextending the structure.

Material Selection

The panel is constructed from 5052-H32 aluminum.

Weight was considered, but rigidity was prioritized. A vehicle-mounted panel must resist deflection under vibration and off-axis loading from attached gear.

The panel itself needed to function as a stable interface before any mounting strategy was finalized. If the panel flexed, the mounting solution would inherit that instability.

6061-T6 offers higher yield strength. That advantage is not relevant in this application. The panel does not approach structural limits under expected load.

This is not a chassis component. It is not subject to impact loading or high structural stress. The governing considerations were sheet fabrication consistency, fatigue resistance under vibration, and long-term durability.

5052-H32 provides adequate structural strength while offering superior formability for sheet fabrication.

Thickness was selected at the outset based on expected load and mounting method. No iteration was required.

Grid Geometry

The slot pattern measures 1.00″ × 0.75″ openings.

The grid does not strictly follow textile PALS spacing.

Fabric systems tolerate slight misalignment because the substrate itself flexes. A rigid aluminum panel does not. Slot spacing was adjusted to better suit metal construction while maintaining compatibility with standard MOLLE pouches.

Standard MOLLE straps interface without issue.

For bolt-through accessories, backing plate dimensions differ from traditional textile PALS hardware. Commercially available 1.00″ × 0.75″ backing plates must be used.

Three additional slots were added along the top edge and three along the bottom edge. These were incorporated to provide flexibility for bracket mounting and alternative accessory attachment points.

The panel was not built around a single mounting method.

Structural Intent

The panel was designed as a load-bearing interface.

It is not decorative.

Equipment mounted to the panel introduces offset load and rotational torque. The panel must resist that load without deflection or distortion.

Before solving how to attach the panel to the vehicle, the panel itself needed to be structurally sound.

Mounting would come next.