dj02

iTrader: (8)

I did this cause I wanted a sexy, functional trunk, that allowed EASY access to my spare tire. Hope this gets stickied and added to DIY section!

Warning: There is alot of reading here, so I hope it is more in-depth than you need. Don't think i'm talking down to you, I just want to make this as easy to understand as possible. Hope you guys like.

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As promised...

Suplies Needed:

• Large uncut piece of MDF, or other strong wood. If buying MDF get 1/2" or 3/4". I used 3/4".
• Carpeting (Link to carpeting I used, from crutchfield.com )
• 3M Super 77 spray adhesive, or comprable adhesive (worked well for this kind of carpeting)
• Wire, Wire, more Wire. Power, Ground, Signal, Amp turn-on, etc.
• Wire management (distribution block(s), etc)
• Wire ends!!!! Get em!
• Zip Ties
• my email address: diskreet(at)gmail.com
• Many, many screws. Like 10+ wood scerws, and 5+ metal screws. More is better!
• Set of hinges. 4 or 6 screw hinges from lowes for like $5 will do.
• L brackets, from lowes. small 4 screw ones are fine. About $5.
• Handle, also about $5 at lowes. MAKE SURE THE SCREWS ARE ABOUT 1" LONG!!!

Tools Needed:

• Screwdrivers, all kinds. More is better here also
• Cordless Drill
• Batteries for drill
• Pliers
• Jig saw
• Circular saw
• Horses
• Flashlight
• Zip Ties
• Safety Goggles
• SHARP razor
• Shears for carpet
• pens, markers, paper for designing and sketching
• other stuff I am forgetting!
• Dremel

Remove everything from trunk; including the plasic piece surrounding the latch hook, the carpeting, the floor, the spare and tools, and the carpeting on the sides. Keep all screws and mounting hardware from the removal.

Take the Carpet that covered the floor board before. Place it over your MDF and trace the edge of the carpet onto your MDF. Leave a few inches of clearence on each of the 3 sides and the 4th should be about 1/2 in the large piece of wood you have.

Using the circular saw, cut off the other like 1/2 of the MDF which you will not need. This is the part with nothing stenciled on it. If you dont understand me here I dont think you need to go any firther with this project.

Now that you have a more managable piece of wood with less edge space, get out the Jig Saw.

Saw the odd little shape out, taking your time with each bend. If you cut a little off its perfectly OK! When you carpet over you will not see the mess-ups, but try to sand/dremel and edges to something smooth. Especially where the wood chips off, which it will.

Test fit the cut out MDF you have now, it should somewhat fit in there well.

Put the side carpeting back on (vertical, with lips touching the floor of trunk) and put the wood back in. Because of the lip of this stiff carpet type stuff, it will not fit perfectly, but thats ok. thats what the razor is for later.


Mark lines on each side of the wood to get something like this shape here:

Make sure that the pieces you cut will be supported on each side by the floor! We dont want you making the middle too skinny and falling in!!!!
I recommend 33" wide in a sedan trunk!

Obviously get out the circular saw and cut these pieces out.

Test fit again, this time with the spare tire in its place!

Put sub box in this time. Make a line a few inches in front of box, but make sure if you cut there that you will have enough room to get the spare out with only the front piece open!

Remove, and cut on that line. Now test fit one more time to make sure!

One last piece to cut, if you want it like mine. Measure from the top of the MDF floor you created in the side corner right in front of the tail light to the top of the trunk interior. measure the rough width of the area you are working in. With a 3/4" MDF floor I used a piece 14 1/2" x 18" in my sedan.

Ok so take it out, its time to carpet!

To carpet place one piece of wood at a time over the carpet. Cut out the piece with about 1 1/2" - 2" extra all around. I recommend getting all pieces cut first then carpeting.

Spray the Carpet and wood with a medium coat of adhesive. let get tacky for about 1-2 mins. Spray again then apply the carpet. make sure you pull tight over the whole piece and smooth on so you dont get bubbles and wrinkles.
If you have tight corners cut a slit in the carpet and cut excess so it doesnt fold on itself. any parts that lift just spray over and push hard, keeping pressure until it is set.


Let set for a while - 15 mins+.

Now lets get the handle on. Cut some carpeting away in that area and drill 2 holes just big enough to get the handle screws in. Rest is self explanitory.



Now lets get the razor out for some fun. Too bad I dont have any good pics for this. Pretty much just put the wood back into place in the trunk, with all carpeting and trim in place. Using the razor cut any spots of carpet that prevent the MDF floor you made from lieing flat. Usually any place the carpeting sidewall stuff curves horizontally to touch the floor cut it off. Now everything sits very level.


Now take the 2 middle piece out and install the hinges. Drill + screws + common sense = finished installing hinges. You may want to drill countersunk pilot holes before carpeting but good luck finding them later.


Put the spare back in now, and the tools if you want, since the wood is staying in place now.

Run all wires you the side now, behind the carpeting stuff that makes the "sides" of the trunk. Dont cut anything yet...

Put the box in now, using L brackets to secure it. I nice trick is mock-mount everything and mark the edge of the L brackets, seating them under the box like I did. Now take the box out. Keep the L brackets in place and screw them in using screws and the drill.
After that you want to put the box back in and screw in to the L brackets. The reason we did this is so you dont have the bottom of the L bracket sticking out, the box is actually sitting ON it! Good idea eh?

So we are down to the home stretch; the amplifier (and possibly capacitor too.)

Mock fit the wood into place. What we want to do it first take the carpeted wood piece we cut earlier and make sure your amp fits well on it. If so we are ready to proceed.


Cut a nice complete slit in the carpeting on the wall, so we can place this new piece we made behind it. You can drill holes in the carpet to run wires through to the front or just cut it and glue it to our board later on like I did. Either way works, but Maybe the way I didn't do it will look cleaner.

This is the hard part: The way I mounted the board is slightly tricky. 2 L brackets on the bottom are no problem, but the top is another story. With the board in place the very top should be resting on a large metal tab of the inner trunk frame usually hidden behind the carpet. You need to get a screw through the wood and the metal to secure this in. It took me many many tries to get it in the metal and a burn or two but if you have a helper hold the wood firmly into place you are set! Once mounted plug in the amp and mount (screw) it on.

Like in the pic you want to get everything routed nicely. Spray carpet adhesive and trim as necessary to get the carpet into place over the piece we made that the amp is mounted on.


If you want the amp lit like mine replace your bulb with an LED bulb from LEDautomotive.com cause it shies right over in that direction.
Night Shot:


Clean up and enjoy!!!






You guys owe me 2 hours of my life if you use this, or just rep or comments. All are welcome!

edit:
One thing you must do is secure the spare tire a new way. Do NOT screw it back into place using the stock hardware. You will not get it out. I suggest using a bungee cord or something to hold it in. Mine isnt actually tied down but it sits well enough that it doesnt move. I don't recommend this though.

civiclover1991

what is the lining on your trunk lid?

MindBomber

^its dynamat, it helps to deaden the sound coming from subs so you don't hear the annoying rattling sound while standing outside your car. Any audio shop should be able to supply it.

thom77

Nicely done. I will follow in your direction on this one.

civicjunkie6207

Its called dynamat

Shihan

Beautiful job

mkkuntz8

thanks for the diy. took on this project this past week. Added a holder for my amp underneath the floor.

mkkuntz8

idk if the pictures worked and for some reason cant find the edit button but there are the links to the photos

http://imageshack.us/photo/my-images...516141338.jpg/

http://imageshack.us/photo/my-images...516141353.jpg/

http://imageshack.us/photo/my-images...516141353.jpg/

Black_EM2

OP re-upload image

Seby05

Hey, I have a couple of questions as I'm about to do this project also.
1. Does theMDF sit directly on the metal floor of the trunk or you put something underneath it so it doesn't rattle?
2. I don't really have many tools, but I found a cheap jigsaw (40 bucks), do I still need the circular saw? Or can I do without? I mean the jigsaw should do the same job, probably just slower right?

thisguy

drmcstford

Diskreet can you fix the photos that are down? Please I want to do this project sometime this weekend or next !

yeroks

Any chance these photos can be re-posted?

05gen7ex

would like pictures... been thinking about doing this for a while

CoMPuLSiVE

Will you be fixing the pictures anytime soon? I need an idea of how i'll be doing this.

BlueEM2

iTrader: (1)

Unfortunately the OP is long gone. He probably hasn't been on here in 5+ years so it's not likely the pictures will get fixed.

kashif977

https://www.civicforums.com/forums/1...re-tire-5.html