Thanks! I made the pod out of mdf and hardboard, covered in fibreglass tissue then got the whole thing flocked so it looks like one moulding:
I'm happy - works well and only intrudes very slightly into the passenger footwell. Only change I would make if doing it again would be to recess the radio so the dials were flush with the sides of the pod, if you see what I mean. Can't go too far back though, or the radio hits the heater.