Trunk lid inserts

[MonstaS4]

I have the same issue with trunk lid fitment as many others have found; the curvature of the lid doesn't match the body. It's high in the middle by a good 5 or 6mm. I've tried leaving the lid in the hot sun for a few days with ratchet straps pulling it into shape, but after a few days without the ratchet straps it just reverts back to the original shape.
I'd love to get Tim's insert bars but it's just not cost effective to ship them to Aus, so it looks like I'm going to have to make them. Can anyone share any wisdom on the right material to use? From what i've read, steel is not ideal due the difference in thermal expansion with glass, and it'll rust. Aluminum appears to be the best choice, but will it be strong enough to hold the required shape? I'm thinking something along the lines of 10mm thick aluminum plate cut to the right curvature and around 10-15mm wide (whatever the distance is between outer & inner skins), installed and bonded in place on it's edge.
Thoughts?
What's a suitable product to bond in place?

[fostia]

I have the same issue with trunk lid fitment as many others have found; the curvature of the lid doesn't match the body. It's high in the middle by a good 5 or 6mm. I've tried leaving the lid in the hot sun for a few days with ratchet straps pulling it into shape, but after a few days without the ratchet straps it just reverts back to the original shape.
I'd love to get Tim's insert bars but it's just not cost effective to ship them to Aus, so it looks like I'm going to have to make them. Can anyone share any wisdom on the right material to use? From what i've read, steel is not ideal due the difference in thermal expansion with glass, and it'll rust. Aluminum appears to be the best choice, but will it be strong enough to hold the required shape? I'm thinking something along the lines of 10mm thick aluminum plate cut to the right curvature and around 10-15mm wide (whatever the distance is between outer & inner skins), installed and bonded in place on it's edge.
Thoughts?
What's a suitable product to bond in place?

Good luck. Even with the bars installed my trunk lid still doesnt fit on the corners. I tried to make my own supports by bending some 5/16 square tube but failed to get the right shape. If you search for the Erik Hanson build thread, he made a pretty slick adjustor out if thick aluminum and bonded L brackets as an alternative idea.

https://www.ffcars.com/threads/reforming-the-trunk-lid.272107/

Costwise, the kit from Tim is reasonable and doesnt cost THAT much to ship so I guess you are saying you dont want to spend $15? Cant imagine Idaho to Austin is much more than Idaho to San Diego. May be worth it to avoid frustration. I bonded mine in with Vinyl Ester Resin from US Composites mixed with chopped fiberglass.

[RoadRacer]

*Australia... :)

[BC Huselton]

I have the same issue with trunk lid fitment as many others have found; the curvature of the lid doesn't match the body. It's high in the middle by a good 5 or 6mm. I've tried leaving the lid in the hot sun for a few days with ratchet straps pulling it into shape, but after a few days without the ratchet straps it just reverts back to the original shape.
I'd love to get Tim's insert bars but it's just not cost effective to ship them to Aus, so it looks like I'm going to have to make them. Can anyone share any wisdom on the right material to use? From what i've read, steel is not ideal due the difference in thermal expansion with glass, and it'll rust. Aluminum appears to be the best choice, but will it be strong enough to hold the required shape? I'm thinking something along the lines of 10mm thick aluminum plate cut to the right curvature and around 10-15mm wide (whatever the distance is between outer & inner skins), installed and bonded in place on it's edge.
Thoughts?
What's a suitable product to bond in place?

Your going the right direction. Al cut to the curve with adjustment 4 adjustment angles on each side to pull the lid into the proper alignment. it works and holds it there over time. Do not bond it. Use the adjustment angles along with washers and 10/23 button head screws to shape it where needed. Bond or glue prevents you from minor changes you may need to make with the final fitment to the body.
139510

[fostia]

*Australia... :)

Damn similar geographic acronyms

[rapidray]

I too had the exact same problem. I decided to approach it in a different direction however. Having worked with fiberglass bodies before I decided to roll the rear of the body slightly to achieve the desired fit. (instead of changing the shape of the lid itself). What I did was build a small bracket that attached to the latch and then to the frame through the latch access hole. I took a piece of 1x1 wood and cut it until I got the desired length just wedging it between the latch and the rear frame. After determining the length I just built a small brace and installed. After I just covered the brace with foam. You can hardly tell its there after the car is assembled and it also firmly attached the latch assembly to the body making the trunk open and close very nicely. I do not unfortunately have a before picture of the trunk fit but I do have one after the brace is installed. Hope this helps. Ray

[MonstaS4]

Good luck. Even with the bars installed my trunk lid still doesnt fit on the corners. I tried to make my own supports by bending some 5/16 square tube but failed to get the right shape. If you search for the Erik Hanson build thread, he made a pretty slick adjustor out if thick aluminum and bonded L brackets as an alternative idea.

https://www.ffcars.com/threads/reforming-the-trunk-lid.272107/

Costwise, the kit from Tim is reasonable and doesnt cost THAT much to ship so I guess you are saying you dont want to spend $15? Cant imagine Idaho to Austin is much more than Idaho to San Diego. May be worth it to avoid frustration. I bonded mine in with Vinyl Ester Resin from US Composites mixed with chopped fiberglass.

As RoadRacer mentioned, I'm in Australia and frustratingly I purchased some smaller items from Tim a couple of months back but hadn't looked at trunk fitment at that point. It would have worked out OK then.....

I had seen Erik's bracket and while it looks great, I was hoping to go with something a little more 'stealth'. I can certainly see the advantages of having a small amount of adjustability rather than bonding in place though so I might end up down this path.

[Svtfreak]

Tim makes his out of 1/2x1/2 square tubing. Everyone who has used them likes them so far. I would add an extension to the top and go over to the mount area and drill and tap a plate welded to the extension to the curved bars. Basically a frame glasses into the lid that the hinge mounts would mount to. Mine is fine but that would really strengthen it up a lot.

[33wanabe]

I also had a fitment issue with the trunk. I found that by relocating the latch brace, on the trunk floor, the lid now fits. You may also have to adj. the height of the deck at the hinge. Just saying it worked for me.