[MENTION=224676]MRG_TRD[/MENTION]
[MENTION=165831]jasxn[/MENTION]
[MENTION=51033]97BlackAckCL[/MENTION]
More storage area pictures and measurements.
So I already had the rear bumper removed for another project, but it doesn’t need to be removed to build and fit in the custom storage. I removed the molding that holds down the carpet next to the rear hatch (the middle clips are easy, the side clips are a PITA) along with the plastic piece with the D-rings by the seats. Then I pulled out the original carpet and hard foam under padding. I removed the foam from the underside edges of the original carpet, but left the felt padding in the middle. I then placed the carpet back into the rear compartment to use at the base for the storage.
Then we just measured and cut the frame out of 3/8” Poplar boards. The side boards (run front to back) were cut to 36 1/4” (length) x 2 3/8” (height) they sit on the plastic rails that run along the wheel well (in the picture my dad has the level resting on one).
The center support rail is 36 1/4” (length) x 3” (height) with a 1 1/2” board nailed (finishing nails) to the top to make it a T for extra support for the lids (We had to cut the bottom of the board to fit over the metal hump on the floor, in 1st picture).
The boards (that run from the driver to passenger side) were cut to 41 3/8” (length) x 3 1/2” (height) and as you can see in the pictures relief cuts were made to make it fit around the seat brackets.
For all the joints/connections we used wood glue and screws.
I then just used black spray paint on the frame and the under side of the lids.
The top piece and lids are 1/2” MDF boards covered in black automotive carpet (held on with spray adhesive and staples), the fixed top piece is 41 ½” (length) x 11” (width), the lids are both 20” (width) x 28” (length) with a 1/2” aluminum U-channel attached (glued and screwed) to the edge of the lid that opens for extra protection. There is about a 3/8” gap between fixed top piece and lids to allow for the piano hinge to be mounted underneath and out of the way. The lids hang over about 1/2”-3/4” by the rear hatch to lift them open.
Still working on a lid support to keep it open on its own, most likely going to just cut a piece of wood that it can rest on.
Some pictures are same but help explain it.