zonzin
Member
I have been wanting to do something with the open compartments in the rear cargo area of my runner since day one. After making center console divider and glove box organizer out of ABS plastic, and inspired by 83mule's aluminum solution, I decided to use it for some covers for the cargo holds. Fun project and makes a world of difference.
Ordered the ABS plastic sheet and the spring loaded push latches at Amazon. Some ABS glue and JB Weld Super Glue is all that was needed. With that size sheet of ABS you will have enough left over to make a glove box and center console organizers.
First step is to cut out some templates from cardboard. Do it carefully and accurately and it will make the ABS cut a lot easier. I just nibbled away at the cardboard with a good pair of scissors and it was pretty easy. Then cut the ABS using a jigsaw, cut a little oversized so you have material to work with to get the perfect fit.
Once the ABS is rough cut I used a belt sander clamped down to the work bench to put the final shape of the covers. It took quite a while only taking bits of material down slowly and checking the fit often, and then making adjustments. ABS works pretty well with the sander making for a great fit. After the fit was perfect, I heated up the ABS with a heat gun so I could form it to the curves on the compartment.
I then attached the push latches to the storage compartments by first shimming them up with a piece of ABS so they clear the edges of the compartment. Now the plastic in the 4runner doesn't adhere to ABS cement so I used the JBW SG to attach them.
I then made 3 of the the "hooks" for the bottom end of the covers out of ABS and glued them to the covers. I used the heat gun to bend them to the correct shape to "catch the inside edge of the compartment. For the little lower cover I made a slot in the compartment and made a catch to insert into it opposite the push latch.
Now everything is secure and doesn't fly out of the compartment. Just give the cover a "bump" with your hand and the covers pop right off. Love it!
What I want to cover:
Templates:
Cut ABS covers:
Bottom cover slot and push latch:
Upper push latch location:
Upper cover "hooks":
Finished product:
.
Ordered the ABS plastic sheet and the spring loaded push latches at Amazon. Some ABS glue and JB Weld Super Glue is all that was needed. With that size sheet of ABS you will have enough left over to make a glove box and center console organizers.
First step is to cut out some templates from cardboard. Do it carefully and accurately and it will make the ABS cut a lot easier. I just nibbled away at the cardboard with a good pair of scissors and it was pretty easy. Then cut the ABS using a jigsaw, cut a little oversized so you have material to work with to get the perfect fit.
Once the ABS is rough cut I used a belt sander clamped down to the work bench to put the final shape of the covers. It took quite a while only taking bits of material down slowly and checking the fit often, and then making adjustments. ABS works pretty well with the sander making for a great fit. After the fit was perfect, I heated up the ABS with a heat gun so I could form it to the curves on the compartment.
I then attached the push latches to the storage compartments by first shimming them up with a piece of ABS so they clear the edges of the compartment. Now the plastic in the 4runner doesn't adhere to ABS cement so I used the JBW SG to attach them.
I then made 3 of the the "hooks" for the bottom end of the covers out of ABS and glued them to the covers. I used the heat gun to bend them to the correct shape to "catch the inside edge of the compartment. For the little lower cover I made a slot in the compartment and made a catch to insert into it opposite the push latch.
Now everything is secure and doesn't fly out of the compartment. Just give the cover a "bump" with your hand and the covers pop right off. Love it!
What I want to cover:
Templates:
Cut ABS covers:
Bottom cover slot and push latch:
Upper push latch location:
Upper cover "hooks":
Finished product:
.
Last edited:
