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Old 07-09-2012, 03:15 PM   #1
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Rear Cargo Cover

Well, I used measurements from another forum on my initial attempt. Big mistake, huge. In my giddiness to build this cover I didn't realize there was no subwoofer in the rear and the plastic surrounds weren't there.

I took my scraps from that debacle and had rough measurements from the first attempt and made a template for the driver side. Flipped it and realized the passenger would be a little different so I made another template. Armed with those measurements from the template I went to work on the new piece of 3/8 melamine my friend gave me.

Made the cuts laid it in and let the cursing begin. It is very subtle but when I looked at my hanging hardtop I realized the rear area tapers in. Made rough marks from the 59 1/4 width and tapered it slightly. That did the trick. Underneath I added about 6 inches of a furring strip held in with a 1 1/4 screw. Tight enough to stay in place but a turn lose so I can swing them out to the side. They got wedged in between the carpet and the bottomside of the tub.

Carpeted it and then installed for the summer. Took all day of fooling around but worth it.
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Old 07-09-2012, 03:53 PM   #2
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That came out nice. I think I can do that with the info you gave..Thanks.

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Old 07-09-2012, 04:14 PM   #3
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I think I still have the wood scrap with measurements. Let me check
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Old 07-09-2012, 04:18 PM   #4
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Here are pics of furring strip underneath. Those are my windows in that bag.

Crappy iPhone pics with a flash
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Old 07-09-2012, 07:55 PM   #5
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Attached is a pic of the dimensions.

In total it should be 31 3/4 inches deep.
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Old 07-09-2012, 10:22 PM   #6
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Quote:
Originally Posted by NY_Joe
Attached is a pic of the dimensions.

In total it should be 31 3/4 inches deep.
Sorry forgot to attach
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Old 07-10-2012, 07:01 AM   #7
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Where did you find the carpet for it and how did you attach it? Staple gun or adhesive or something else? Also, is the furring strip locking it down from beneath? I've seen other DIY covers that were just bolted to the frame, but yours doesn't look that way.
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Old 07-10-2012, 10:26 PM   #8
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Originally Posted by Scarlet Begonia View Post
Where did you find the carpet for it and how did you attach it? Staple gun or adhesive or something else?
I found the carpet at Lowes. Checked auto stores and no one had auto carpet. It is indoor/outdoor all purpose carpet. It came in a 6 x8 roll. It is grey and matches the carpet pretty well. I couldn't find spray adhesive easilyin Lowe's so I gave up. I just made sure it was pulled tight and used a nail gun. It is held down fine.

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Originally Posted by Scarlet Begonia View Post
Also, is the furring strip locking it down from beneath? I've seen other DIY covers that were just bolted to the frame, but yours doesn't look that way.
I have researched this on this forum and another. Some people extended the cover over the top of tub and bolted through the hardtop holes. I did not like that look.

The people that kept it in the tub fabricated metal brackets or braces which posed a safety risk b/c of sharp edges. I was going to let it wedge in there and hope it stayed up that way.

However, when I was test fitting I was trying to find a way to keep one side up and in place when i went around to the other. I had the furring strip in my garage and uses a small piece. It worked so well i figured let me screw 2 pieces on and see how it holds up.

The furring strip is basically locking it down and also keeping it from dropping down in the rear. The other edge is wedged under the rear door. To remove, just twist the furring strips in and maneuver the piece out. I can try and get better pics if you want.
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Old 07-11-2012, 06:21 AM   #9
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I can try and get better pics if you want.
that would be great if you could. I'm more of a "visual" person, so I do better when I can see how something is done. Thanks for the info!
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Old 07-11-2012, 08:46 PM   #10
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Originally Posted by Scarlet Begonia

that would be great if you could. I'm more of a "visual" person, so I do better when I can see how something is done. Thanks for the info!
Here are a few pics. Hope they help.

You can see where the furring strip is attached to the board in the first pic.

The second pic is the gap I am referring to which you can we clearer in this long shot.

The third pic is the furring strip in the gap.

The fourth pic is the view from above. Shows the furring strip locking in below and that the cover sits flush. This will allow the hard top install with the cover on.

The fifth is a bracket near the door that can possibly be used to hold a stronger/longer brace.
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Old 07-11-2012, 08:52 PM   #11
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God I wish I was handy. Great job with this DIY mod.
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Old 07-11-2012, 10:36 PM   #12
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God I wish I was handy. Great job with this DIY mod.
Thanks. Saw so many versions and adapted to what I wanted.

No need to be super handy. Piece of wood, carpet, staple gun, pencil, tape measure, long ruler and a circular saw. Trace it out and cut it out.
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Old 07-12-2012, 07:32 AM   #13
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Maybe I'll use your template and make a lowes run.
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Old 07-12-2012, 07:36 AM   #14
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that came out nice! does it vibrate a lot or sit pretty snug?
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Old 07-12-2012, 08:47 AM   #15
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Quote:
Originally Posted by NY_Joe

Here are a few pics. Hope they help.

You can see where the furring strip is attached to the board in the first pic.

The second pic is the gap I am referring to which you can we clearer in this long shot.

The third pic is the furring strip in the gap.

The fourth pic is the view from above. Shows the furring strip locking in below and that the cover sits flush. This will allow the hard top install with the cover on.

The fifth is a bracket near the door that can possibly be used to hold a stronger/longer brace.
Thank you so much! That is helpful. I like that it sits flush even though I probably would remove the cover if I had the hard top on.
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Old 07-12-2012, 10:58 AM   #16
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Maybe I'll use your template and make a lowes run.
If you have the subwoofer in the rear my template will work. I also have the plastic surrounds still on.

IF you didn't want to make all the cuts you could also just shoot striaght down to the door after that 8 1/4 inch cut in at the top. The only other cut would be to fit around the soft top brackets.
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Old 07-12-2012, 11:00 AM   #17
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that came out nice! does it vibrate a lot or sit pretty snug?
It sits really snug. It would drive me crazy if it rattled.

Pre carpet it squeaked from rubbing the body a little. I trimmed and carpeted and all is fine now.
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Old 07-12-2012, 11:02 AM   #18
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Thank you so much! That is helpful. I like that it sits flush even though I probably would remove the cover if I had the hard top on.
Glad the extra pics helped. If it helps someone else out, then I'm happy.

For winter, I will most likely remove since hardtop will be on and windows are tinted on hardtop.
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Old 07-12-2012, 12:57 PM   #19
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I'm a 40 yr old and will be asking my step dad to help. He has tools and is building a gazebo, if he can do that, he should bang the cutting out in no time.

So as far as the decking material goes that you used, is that sold at lowes /hd ?
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Old 07-12-2012, 09:12 PM   #20
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I'm a 40 yr old and will be asking my step dad to help. He has tools and is building a gazebo, if he can do that, he should bang the cutting out in no time.

So as far as the decking material goes that you used, is that sold at lowes /hd ?
Yes, lowes. I originally bought 3/8 particleboard sheet. 4x8.

All the cuts were wrong and was going to purchase it again. My friend gave me 3/8 piece of melamine. It was easy to work with but the particle board was a little stronger.

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