BEWARE this thing is UGLY in this stage.
but I promise you once Im done covering it you will be AMAZED!!!!
so get a good look at it now.
Ok here is the box
in the pre carpet stage. (Ill post carpeted pics tomorrow)
a quick how to. goes like this.
Make a mold of your floorboard , steps, Tape up your carpet area (where the mold will be) tape it using 2" masking tape do this both ways then using some cheap spray glue
glue a layer of (garbage bag material) thin visqueen, drop cloth, this will be the mold release. then get out your fiberglass put down some mat and woven till your happy.
wait to dry then remove for trimming.
Build your access door I used 3/4 inch plywood 8 layer stuff. I cut the doors so that
I would not need a hinge, also I left plenty of play for the carpet.
Then I rigged the top piece to the bottom piece using some temporary wood wedges.
once the upper and lower pieces were in alignment. I wrapped the 2 pieces with some
fleece. (basically a baby blanket or similar) once i was happy with the shape I used
fiberglass resin to saturate the fleece into shape. wait to dry then trim.
Also I installed a few braces for strength .
Once dry Grind to smooth and go get some carpet. (dont forget to trial fit many times....)
see pics below.
while doing this keep in mind how you will want your access lid to turn out.
this is installed side view (again NO CARPET YET)
view from front looking back
looking in from Drivers rear door
close up of door countersink
nice side view from psg side One seat down one seat up.
Now some out of the truck views
the whole box with doors
the underside basically the mold of the rear floorboard.
A close up of my internal gussets/aka braces
Last edited by A8050266 : 12-08-2008 at 03:32 PM.