My Rear Shelf Mod!

[David Hodgkins]

So tonight I decided to finally tackle a mod I've wanted to do for a long time!

First I reaped destruction on my cockpit wall with this little baby:

http://thefactoryfiveforum.com/attachment.php?attachmentid=8143&d=1330575508

I cleco'd the rear cockpit wall in real quick so you can see where the new shelf will be:

http://thefactoryfiveforum.com/attachment.php?attachmentid=8142&d=1330575507

The next step will be to cut this piece of aluminum for the new rear wall:

http://thefactoryfiveforum.com/attachment.php?attachmentid=8144&d=1330575509

I'm going to do it a bit differently. I'm planning to keep my tabs straight and cut slots for them in the trunk. I'll silicone it and maybe bend the tabs over with a hammer after install...

I'm working with a boat canvas guy on creating a cover for the front of the shelf that will be rigid and held in place with snaps.

Thoughts so far?

:)

[Gumball]

Cool - looking forward to seeing how this one turns out.

[WIS89]

David-

My first thought is how in the world do you plan on fitting that freezer into that shelf?

I like it, and it looks good. Do you plan on covering the canvas with carpeting? If not as you know, it is likely not going to be "hidden."

The only other concern that I have is that anything heavy in this area becomes a missile hazard with hard braking. Just spit-balling, but perhaps a fold up or down door with a piano hinge and securing handle?

I like the space, and it should provide some decent room for storage. Please don't take my points as criticism; just my opinions, which are not worth very much...

Good luck with the rest of your project!!

Regards,

Steve

[Mike N]

The only other concern that I have is that anything heavy in this area becomes a missile hazard with hard braking. Just spit-balling, but perhaps a fold up or down door with a piano hinge and securing handle?

I agree, I think from a safety perspective you definitely don't want CD's, iPod, GPS, sunglasses etc flying around the cockpit if you are in some kind of avoidance maneuver. A rigid door on a piano hinge makes the most sense but is also the least practical as it can only be as wide as the gap between the seats or you can't open it. What would work well is a door similar to a garage door that is on tracks or single piece door on a pivot point so that it can swing up out of the way into the trunk area.

[skullandbones]

Hi David,
I've spent a lot of time cruising in cramped spaces (sail boats). You learn how to eek out every square inch available for storage. So I can appreciate your project. I would go with a soft door/cover. If your canvas guy is good he can fab a cover that will have the correct fastners probably not button snaps that will survive any accident (even use short battens to stiffen but probably not necessary). You have a small access of 34x3 up to about 1 inch in front of the bars and belt straps. I suppose that would be for rain gear or other soft stuff that you don't use often but need on occasion. There is a ready access of 6x13 that is the one you could use while driving say for a cooler. You could have the canvas guy install a vertical zipper (#10 very heavy) in the center and cover the whole thing with material to match your side panels. That would make it pretty plush. You, also, might get the added benefit of a good sound dampener if the door/cover is stuffed with the correct batting. I believe you will have a mod that is very unique and functional. Good luck, WEK.

[riptide motorsport]

Looks good, can never have enough storage in these cars. Keep up the good work, likw to see the finished product.....Steven

[MPTech]

Looks good David! I have the same mod planned for mine.
I was going to leave a little more aluminum panel on the sides (a couple inches) and a lip on the bottom (an inch or so) to help hold items in there.
I was only planning to toss jackets, small blankets, sunglasses, etc in there. Also thought about rigging one on those grocery / cargo nets that could be hidden in the top, but fastened in the bottom corners when needed to help hold items in there.

Just curious, where does your cross beam hit your seat belt holes at? About 1/4 to 1/3 of my seat belt hole is covered by the cross beam. I thought about adjusting it up a little (still want the seat belt to lie on the beam, not the aluminum panel edge).

Great mod, keep us posted.
What is your reasoning behind "planning to keep my tabs straight and cut slots for them in the trunk. I'll silicone it and maybe bend the tabs over with a hammer after install..."
This sounds harder than bending the tabs and riveting them.

[David Hodgkins]

The plan is to have a rigid plastic cover, covered by carpet on the outside and a tight canvas mesh on the inside. It will be secured with snaps top and bottom.

I made a wall template today. You can also see that I'm getting close to finishing the cockpit sound deadening:

http://thefactoryfiveforum.com/attachment.php?attachmentid=8324&d=1331688293

http://thefactoryfiveforum.com/attachment.php?attachmentid=8323&d=1331688292

http://thefactoryfiveforum.com/attachment.php?attachmentid=8322&d=1331688291

http://thefactoryfiveforum.com/attachment.php?attachmentid=8321&d=1331688289

It will be deep enough to be able to hold a pair of jackets. The wall will be polished on both sides and I'm having carpet made for both trunk sections that will have a soft backing so it can be taken in and out.

Is there enough room in front of the rear hoop for a trunk hinge?

Feel free to post additional comments; they are appreciated!

:)

[David Hodgkins]

... What is your reasoning behind "planning to keep my tabs straight and cut slots for them in the trunk. I'll silicone it and maybe bend the tabs over with a hammer after install..."
This sounds harder than bending the tabs and riveting them.

I want the trunk to not show any tabs. If you look atthe pics above, the few tabs that exist are behind the panel next to it, not on top. The side walls went in before the upper trunk floor, and the lower trunk is tucked under the upper trunk floor as well.

:)

[Jeff Kleiner]

Is there enough room in front of the rear hoop for a trunk hinge?

Yes.

Jeff

[CraigS]

I plan to do something similiar. I figure that if I use it for hats,jackets,gloves that will be great and still safe.

[Cameron Autosports]

Here are a couple pictures of a MKII that I am restoring for a customer. I built this shelf not for storage but to have the roll bar exposed behind the seat, more like the original. I also added the support bars under the dash. I have fabricated all new aluminum on this car with larger foot boxed, firewall forward and special trunk panels.

[E-Ticket Ride]

Damn it!!!
You guys and your "really cool and useful" ideas...
Here I thought I was done messing with sheet metal.

Looks great though! Good Job David.
CL

[David Hodgkins]

Today I cut the actual panel. I left tabs on it and cut slots into the trunk for the tabs to slide in to...

http://thefactoryfiveforum.com/attachment.php?attachmentid=8356&d=1331859913

http://thefactoryfiveforum.com/attachment.php?attachmentid=8355&d=1331859912

http://thefactoryfiveforum.com/attachment.php?attachmentid=8353&d=1331859910

http://thefactoryfiveforum.com/attachment.php?attachmentid=8352&d=1331859909

Now that the wall is fitted, I'm pulling it back out for polishing.

[Cameron Autosports]

Great Job David!

[MPTech]

Very clean install Dave and the polished panels look great.

question: how did you determine the arch of the new panel? (based off of the rear bulkhead or the rear / hinge support hoop? or something else?)
very cool, I'm planning to cut my bulkhead hole and back panel this weekend.

[Cameron Autosports]

Hi David,
If you pre-fit the body over the rear bulkhead you can clearance for a bubble seal there. It will keep the cockpit area free of a lot of dust and probably the trunk area also. Looking forward to seeing your car next month.

[David Hodgkins]

After doing some more fitting I decided to move on to polishing the panel and bring the trunk shine up as well. This resulted in 3 full dys of polishing!

The polishing process with Nuvite compound takes three steps to bring up to full shine. Here is the new wall after the first step:

http://thefactoryfiveforum.com/attachment.php?attachmentid=8401&d=1332123240

http://thefactoryfiveforum.com/attachment.php?attachmentid=8400&d=1332123238

My trunk hasn't been polished since I got registered over 2 years ago. Here it is after I finished the floor. I still have to do the sides...

http://thefactoryfiveforum.com/attachment.php?attachmentid=8397&d=1332122496

http://thefactoryfiveforum.com/attachment.php?attachmentid=8395&d=1332122494

http://thefactoryfiveforum.com/attachment.php?attachmentid=8394&d=1332122492

I'll finish the new wall later this week. I also need to get at least the rear cockpitcarpeted and polish some panels up front before I can go get the body.

More pics after the new rear wall is finished polishing and installed...

:)

[frankeeski]

Tic-toc buddy. You'd better kick it into high gear. I'm more than happy to lend a hand if you need it Dave. HB is right around the corner. My short block is nearly finished but I do not plan on doing anything to my car until after HB. So give me a holler if you need a hand or two.

[David Hodgkins]

Tic-toc is right! I have to carpet the rear cockpit wall before I can mount the body, and I'm almost done touching up the aluminum. I'm hoping to get to Jeff's this week to pick up the body. Then a mad dash to assemble everything before HB. April is going to be a busy show month, but I'm might have to go into incubation mode to get it ready.

Frank I'll call you later this week. At this point I don't see how the rollbar will get done. If I can get through the rest of the assemby it will probably be the last thing done.

:)