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I substantially rebuilt the glove box in Sven. I use it to support a drink holder that hangs on the door's upper edge (the kind that will hang on glove box door or into a window slot). So I learned how to make the box + door sturdy.
Door's front is made of fairly thick fairly stiff foam. I expect you can cut into it and carve it out. Foam front panel is GLUED to the plastic lid. Enough stress or age etc. will detach the glue.
Wifemobile 240 has weakened plastic near the hinge. Weight bearing down on top edge of closed door flexes plastic at the hinge so that the door latch lets go occasionally.
The plastic likes to crack at the screw mount holes on the box itself. I reinforced several holes with epoxy.
On the wifemobile I had to reinforce the box's latch area because the plastic was cracked. I put a bit of aluminum stock across, inside the box, where the latch is supposed to bite onto the plastic edge. The photo has a lot of glare but I think you can see it. It's fastened with 2 rivets plus epoxy; no room there for screws + nuts. I tried epoxy alone at first - it let go. A Dremel cut the notch in aluminum for the latch.
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Sven: '89 245 NA, 951 ECU, expanded air dam, forward belly pan reaches oem belly pan, airbox heater upgraded, E-fan, 205/65-15 at 50 psi, IPD sways, no a/c-p/s belt, E-Codes, amber front corner reflectors, aero front face, quad horns, tach, small clock.
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