Over the last few weeks I have knocked up some replacement rear panel trims and a bit of a “boot” for some soft top security. I know this is nothing compared to some of the fab work on this site, but thought I would do a bit of a spiel for that very reason, so those less gifted like myself can see that there are some jobs you can have a crack at and also it is a bit of an alternative to checker plate.
The reason for the panel trims was to fit some bigger speakers and get rid of the original 4” ones in the trim, the boot was to have somewhere to stash a backpack when down the beach or shops – only as secure as a barrel lock, but out of site and prevents the snatch and grabs plus I wanted something I could pull out with a few bolts if I needed to chuck something big in the back.
The other reason is that everything came from the local Bunnings except for the black screws (pick a car shop) so good for a weekender. The original panel trims are melamine and foam but I substituted for MDF and coreflute (plastic cardboard). I made attachments for the boot when I built my rollbar, but a bit of angle can be screwed to the panel trim instead.
The basic shopping list was:
- 1 sheet of 3mm MDF for trim, 6mm for boot, can’t remember dimensions, 1 sheet per job & matching size sheet of coreflute for each. Glue, I used a spray on. Some vinyl, I bought 1m for the trims and 1m for boot, boot claimed the offcuts from the trims, the width is something weird like 1330mm. Assorted bolts and fixings for boot, for the panel trims I used wall plugs and screws instead of the shit (and difficult to replicate) original clips.
- Optional aluminium trim, 16 X 12mm channel. I added this for a bit of edge protection but it was the hardest part of the job with lots of cuts (& mistakes) for the end pieces. I also used a length of 25X25X1.2mm ali tube for some added stiffness for the top shelf. I fixed the channel with black silicon.
Total cost about $50 for either trims or boot (depending on fixings), another $50 if you go the ali as well
The basic tools were:
- Jigsaw , drill, staple gun, hacksaw &/or grinder if you go for the ali trim, some measuring stuff
- Whatever else you have in the shed, I also used files, a hot glue gun at first but gave up on that one, a power saw, a few clamps and a bench.
So how I did it:
1. Glue MDF and corflute & weigh it down.
2. Go drink beer and come back later.
3. Mark out using original panel trim or get into the cardboard and markers for the boot and cut to suit.
4. Glue on vinyl and weigh down, return to step 2, then cut vinyl with enough overlap for a good fold. For radius edges cut wedges out, for corners cut 45 degrees – look at original panel for guide. Staple down, glue also if you get the urge (fiddley). Vinyl joints in the boot are covered with 100mphr/gaffa tape and then stapled
5. If using ali trim, cut with grinder/hacksaw/drop saw and attach somehow (I used silicon)
6. Install. If using screws and wall plugs for panel trim, mark hole centres from old trim and predrill holes, then fit plugs and screw in place. For boot, you’ll work it out.
7. Write some shit, post online and await ridicule.
8. See step 2.
