After lusting after a JDM hard cargo cover and being fed up with the soft USDM one, I decided to build my own.
If you want to use my method, do so at your own risk. I will not be held responsible for ruining anything or wasting your time, or getting injured. These steps are to be used as a guide only.
First off, Here's a list of necessary materials:
18"x48"x1/2" MDF
2 yards headliner material
2 yards vinyl (or whatever fabric you want to cover the cover with
18x24" foam presentation board
3m spray adhesive for headliners
10 ft 1" SCH 40 PVC pipe
4-90 degree albows for 1" PVC
4-1" pipe hangers
black spray paint
8-1/2" screws
1: Measure and cut the 1/2" MDF to the size you want. I had the soft cover to use as a template. I cut the MDF smaller to give a little room for the upcoming sub to move some air. I left about 1.5" on each side.
Your board should look like this (the vinyl is already on the bottom)
3: Spray the MDF and the foam side of the headliner material with the spray adhesive
4: Let set for 5 minutes
5: Place headliner material on MDF. It should adhere immediately, so be careful while putting it on.
6: Repeat for other side of MDF
At this point you need to think about where your seams are going to be. I covered the bottom first and stapled it along the edges. When I covered the top, I wrapped it around the bottom, folded it under so the cut edges were not shown, and stapled. My method means that staples are visible, but only from the bottom, which I thought was acceptable. Some would go with a similar method, but cover the bottom last, and do so by wrapping a piece of cardboard or foamboard, and gluing it on. My method is easier, but does leave staples shown on the bottom.
7: Cover one side with vinyl. I didn't use glue, just pulled tight and stapled on the ends. Here's what you should have at this point:
8: I decided to get fancy and cut the scion emblem out of 1/4" foamboard and put it under the vinyl. Here's what the emblem looks like. That is a spray can next to it to give you an idea of the size.
9: Center, then spray glue the foam in place on top of the headliner material.
10: Spray the foam and headliner around it, and spray the inside of the vinyl. Be sure not to spray too much on the vinyl, as it can seep through and screw up your vinyl.
11: Give it 5 minutes
12: Here comes the toughest part: work the vinyl into the sunken-in parts and all around. I had some difficulty stretching the material in. A heat gun helps soften the material, but be careful, you can ruin the vinyl with excessive heat.
13: What I did was take a pillow and sit on it on top of the raised portion to adhere the vinyl to the headliner and foam.
14: Wrap and staple.
Congrats! You are done with the cover, now you need a way to mount it.
If you look, you'll notice the hooks in the rear have a recessed area around them, and it turns out a 1" PVC pipe fits in there perfectly.
15: Make a U-section out of two 90 degree elbows and three sections of PVC. For the center section, measure twice, cut once. I think I used 6.5" between the inner parts of the pipes. For length, I went with 20" It is important that these be fairly long. It's tough to explain, but for this to be removeable easily, the longer they are, the easier it will be to pull them out. Trust me, use 20"
16: Go ahead and make an identical U-Section.
17: Paint the PVC and the pipe hangers. I used black spray paint. I had galvanized hangers, which paint doesn't adhere to well, so I hit them with a coat of primer first.
Here comes the assembly, which should be done in the car for a good fit. A friend would be helpful to hold the cover in place.
18: With the board where you want it, place one of the U-Sections in the side. Screw it into place.
19: Repeat for the other side and you are done! With this method of attachment, the U-sections of PVC can rotate down, which means that when you lift up on the cover, the PVC will turn, and allow the cover to easliy be pulled off.
where does it hook? are there hooks on the side? sorry ive never looked at mine to see. looks nice though!
:clap:
J_A_Trevino
06-23-2005, 03:23 AM
pretty cool, good job.
stick_1NZ
06-23-2005, 03:29 AM
Another money-saving DIY. Good job.
3rd World Approved!
Max
06-23-2005, 03:36 AM
where does it hook? are there hooks on the side?
:clap:
It does not hook, it fits in the indentations the hooks for the cargo cover are in. It is very similar to the JDM method of attachment, only those are spring loaded. The fitment is very rigid.
Thanks for your compliments. I should note that I have never done any upholstery work. My first time in a fabric store was to look for the vinyl. Good luck to anyone who attempts this, It's really not that hard. I would have had this done in one evening had I not had to let the paint dry.
eggie
06-23-2005, 03:47 AM
Good job.
That said, I think if you would have used some spray adhesive around the logo then when attaching the material tucked it in and let it dry. You would have ended up with a more pronounced logo.
Still GJ!
Big_Bird
06-23-2005, 03:57 AM
not bad man, i like it
mike51392
06-23-2005, 04:00 AM
damn great - great job im def... going to give this a try
Max
06-23-2005, 04:03 AM
Good job.
That said, I think if you would have used some spray adhesive around the logo then when attaching the material tucked it in and let it dry. You would have ended up with a more pronounced logo.
Still GJ!
Man I used all kinds of adhesive. This was the best I could get. I couldn't get it tucked very well, but it looks good in person.
Max
06-23-2005, 04:04 AM
damn great - great job im def... going to give this a try
Please update with pics when you get it done.
x2_da_b
06-23-2005, 04:13 AM
not a bad idea, if i have time at work i will try to make something like that, i would just modify the way it mounts a little though.
Max
06-23-2005, 04:35 AM
not a bad idea, if i have time at work i will try to make something like that, i would just modify the way it mounts a little though.
How? It works very well, and very securely. It lifts out easily, and is quite secure. Let me know how to improve, please.
windowtint
06-23-2005, 04:36 AM
Good job Max. I can always appreciate when someone takes some initiative and goes to the trouble of making something for themselves. Congrats.
Max
06-23-2005, 05:25 AM
Good job Max. I can always appreciate when someone takes some initiative and goes to the trouble of making something for themselves. Congrats.
Thanks a ton! This means a lot coming from one of the more innovative people on this board.
Since this mod requires no modifications to the car itself, it's easy to get some guts to try this without fear of screwing something up.
XBman
06-23-2005, 07:38 AM
wait, gow is it held up? where do the pcp pipes go into?
Box916
06-23-2005, 07:57 AM
Ok, so am I the only person who doesn't know what MDF is?
And why would you want a hard rear cover? Just a couple of questions...thanks!!
Styalz
06-23-2005, 11:27 AM
Nice job broda!
Digger
06-23-2005, 12:30 PM
MDF... pressboard. Kinda like plywood but stays stonger and flatter and resists warping.. just don't get it wet. :)
Max
06-23-2005, 12:59 PM
wait, gow is it held up? where do the pcp pipes go into?
Look back there, there are two indentions around the clips which the Scion cargo cover clips in to.
Ok, so am I the only person who doesn't know what MDF is?
And why would you want a hard rear cover? Just a couple of questions...thanks!!
MDF stands for medium density fiberboard. Plywood would also work, but it's more expensive. I wanted to replace the stock cover cause it looks like crap. I need a cover to hide the sub I am going to put in there. I wanted something which wouldn't sag like the Scion one does.
x2_da_b
06-23-2005, 02:03 PM
the way i was thinking of modifying it is because the sub box i have come up pretty high so i would have to make leg or something to keep it away from the speakers.i like that idea though of the pipes it looks hot and i was also thinking of buying that scion cover but it does look flimbsy.
dgHotLava
06-23-2005, 02:03 PM
Ok, so am I the only person who doesn't know what MDF is?
And why would you want a hard rear cover? Just a couple of questions...thanks!!
MDF = Medium Density Fibreboard
here is a quick info sheet on it..
http://www.design-technology.org/mdf.htm
i like the hard cover idea. it won't flap like a soft cover.
it can support some weight. it hide whatever is below it.
Max, how much weight do you think it can hold?
windowtint
06-23-2005, 02:11 PM
...and you could set something on top of the cover Max made should you want to. It becomes another usable shelf.
And XBMAN.. it's PVC pipe, not PCP. Two totally different things.. :)
dgHotLava
06-23-2005, 02:17 PM
...
And XBMAN.. it's PVC pipe, not PCP. Two totally different things.. :)
is that why my kitchen pipes look the way the do....
Max
06-23-2005, 02:24 PM
Max, how much weight do you think it can hold?
That I don't know. I wouldn't want to put any more than 20 lbs on it. It is pretty stable, and the PVC doesn't seem like it can slip out. I do not want to test this, because if I were to break the MDF, I'd have to start over completely.
svnwrnch
06-23-2005, 02:44 PM
Great Job! I'm gonna do this myself, Just one thing I am gonna to add the word "scion" under the symbol, i cant copy you completly!
sciondude410
06-23-2005, 02:47 PM
Has anyone attempted making a fiberglass version? Maybe using the US cover as a template then just laying fiberglass matt a few layers think then cutting to fit and sanding it to finish it off? I would just think it would be lighter and little smaller. Maybe I will try this soon. I just need to get a template.
Max
06-23-2005, 02:58 PM
Great Job! I'm gonna do this myself, Just one thing I am gonna to add the word "scion" under the symbol, i cant copy you completly!
I completely don't care if you want to copy. I considered putting the lettering on mine, but the vinyl was pretty tough to work with, and I don't think it would have come out well, but good luck. If I get bored enough, I may attempt version two in a different fabric. This was my first time doing anything like this and I learned a lot. I think my next version will be killer.
svnwrnch
06-24-2005, 12:42 AM
A fiberglass version would be awsome if you are good with fiberglass then the possabilities would be endless with the lettering and symbols you could put in there, amp racks, etc.
Max
06-24-2005, 01:36 AM
I have never done ay fiberglass work, but then again, I never did upholstery before this either....
n2htwlz
06-24-2005, 01:43 AM
Im not trying to thread hijack, just sharing. :P
Heres mine I did a few months back. Fits end to end and tailgate to back of the seat. Its held up by 2 aluminum L chanels that were cut the length of the sides and screwed to the side panels. It can hold quite a bit I have seen, my wife will come home from the grocery store with food and stuff pilled on top of it when there isnt any room left under it. I added the speakers to it because I wasnt able to hear the ones in the side panels anymore, and the bazooka got louder as well. I covered it in bedliner spray.
http://www.scionlife.com/tech/images/cargo_cover_diy_xb/DSC00478.jpg
windowtint
06-24-2005, 02:31 AM
other than the "screwed to the side panels" - sounds/looks great. Then again, you can't see the L-brackets... so what's it matter I guess. The only other way around the mounting problem is to extend your cover to each side with upward angled "wings" that rest on the light grey portion under the quarter glass
x2_da_b
06-24-2005, 03:57 AM
well i made it today, it fits really tight and rest right against the top of my box perfectly. i didn't put any logo or any thing on it. i think it makes my subs louder also,well when the door is closed, makes a good shelf, when i went to the super market before i had to put everything in the back seat because of my box, now i have room to put stuff back there. sorry no pics. i'm going to throw some neon lights underneath the board and a plug on it for when i take it out, maybe tomorrow if i get a chance.
shorberg
06-24-2005, 04:12 AM
that is way cool. with a little work, it could look factory. the vinyl hangs off the sides a little too much for me, other than that i like it alot. i really like the scion logo in the center!
Max2k
06-24-2005, 04:42 AM
N2twhlz: Did you just trace the cargo cover and cut it from wood?
Max
06-24-2005, 04:52 AM
that is way cool. with a little work, it could look factory. the vinyl hangs off the sides a little too much for me, other than that i like it alot. i really like the scion logo in the center!
Yeah I need to fix that vinyl. I'll work on it soon. The Scion logo looks awesome in person.
Max
06-24-2005, 04:53 AM
N2twhlz: Did you just trace the cargo cover and cut it from wood?
I realize the question was not directed at me, but that's exactly what I did.
n2htwlz
06-24-2005, 05:56 AM
N2twhlz: Did you just trace the cargo cover and cut it from wood?
Exactly, I traced the stock p.o.s and then extended the measurement out to each end. Its made of particle board and counter sunk allen head bolts hold it to the brackets.
n2htwlz
06-24-2005, 05:58 AM
N2twhlz: Did you just trace the cargo cover and cut it from wood?
I realize the question was not directed at me, but that's exactly what I did.
I still like the fact that you didnt have to make a mount on the sides, using what was already there is slick..
XBman
06-24-2005, 07:14 AM
...and you could set something on top of the cover Max made should you want to. It becomes another usable shelf.
And XBMAN.. it's PVC pipe, not PCP. Two totally different things.. :)
i kno it was pvc piping, i accidently hit the c key... oopppsss....
Max
07-20-2005, 04:23 AM
A little warning to those considering this... The vinyl/PVC combination does not work well. Any bump in the road and the movement of the two leads to a lot of squeaking. I made another one tonight. I found some fabric which very closely matches the seat fabric on the sides. I also used plywood this time rather than MDF. I was a little concerned with the MDF sagging over time, although it appeared fine so far. I got everything done, start to finish, in well under two hours. Upon initial inspection the squeaks are gone, although I have not driven around yet. I did not put a raised emblem. I have other plans. It was dark when I put the cover in, so no pics yet. I'll get them up tomorrow evening.
koalaty2
07-20-2005, 04:53 AM
Some very inventive thinking, and a great ideas. Everyone modifies and changes to their own liking. That is great. Will have to put this on my list of personally engineered (home-made) items. Try to keep all my items as personally engineered as possible. Allows for more mods quicker, due to expense, and lets me spend time with the box, which I enjoy. The CAI, graphic, tails, and bug deflector (covered in white, trimmed in black) are purchased, but I installed them with some minor changes. Arm rest, panic handle covers, visor covers, headrest covers, shift boot, CAI grill and a few painting mods are all personally engineered. About 20 mods, and 20+ to go. Wheels are expensive, so they will be a while. Due the stock ones are painted. Enjoy the Box, and as someone said. "Have it your way".
suprfli
07-20-2005, 06:46 AM
great job! thanks for the how-to!!
Max
07-20-2005, 02:31 PM
Woohoo! No squeaks or rattles.
And for those not wanting to measure the distance between the sides, I used 51 1/4" from end to end and it's a good tight fit.
The fabric has the same texture as the seats, but it is darker. Pics tonight after work.
Max
07-20-2005, 11:13 PM
I got some pics!
The first shows the whole thing, the second shows the gap I left on the side, and the last two show the comparison between the seat fabric and the cover fabric. The texture appears the same in person, but it is darker than the seat fabric. The difference in color is not as noticeable in person as it is in the picture, but there is a slight difference.
wow, great job brother, what was the total cost...installed lol
Big_Pimpin'
12-05-2005, 08:28 AM
Very Nice Job!!!
I was thinking of trying something close to what you've done, but gotta wait for warmer weather. Just To darn cold in Michigan right now to be working in the shop.
I was thinking of using fiberglass or MDF, and putting some cup holders in it for tailgate parties. :crazy: Maybe even try to put an extension that would fold out a little farther. As you can tell, it would not be for everyday use, just a handful of weekends a season. If anyone has an extension or suggestions, let us know.
Again, very nice and thanks for the inspiration. :bow:
Max
12-05-2005, 05:40 PM
wow, great job brother, what was the total cost...installed lol
Probably around $40 or $50, depending on the material you use.
Bartx7000
07-06-2006, 05:17 AM
Cool I was going to make onea out of masonite and cover it in black vinyl. I never got around to it but now after seeing those one, I think I will have to do it.
TheScionicMan
07-06-2006, 06:05 AM
Love the mounting idea with the folding pvc. They could maybe even double as table legs if it gets removed at shows, etc...
Archngl
07-06-2006, 04:11 PM
And why would you want a hard rear cover?
I want one to improve my subwoofer sound and to hide the fact that I have a subwoofer... lol
theft = bad.
Max
07-06-2006, 06:08 PM
Thanks for the comments. Post pics if you make one.
cherryBox
08-22-2006, 09:49 PM
n2htwhlz - i'd like to see the underside of your mounting setup, if possible
cierrecart
08-24-2006, 08:37 PM
I'm thinking about making one that has a dished tray built into it to hold the kids toys and snacks when on road trips. I suppose it would be as easy as making the basic tray, cutting a hole and screwing something like a shallow rubbermaid tray to the underside.
Jagonza
10-15-2007, 05:16 PM
can some one post a copy of the pattern where i can download it, or email it to me at jagonza@aol.com. i want to make a hard cover but need a good pattern
Puz06xB
06-10-2011, 04:33 PM
Reviving an old thread here, seen this one on here for a while and can't believe there's not been more input on it! So I took a shot at it with an old piece of plywood and some trial n error...
After fooling with several curtain and shower rods I decided on one of those walmart car clothes rods (happened to have 1 I never used) and bought a second after I got the 1st to fit to my liking. Then picked up some black rubber stoppers like you'd find on the end of a stool leg at home depot. I reversed them though by drilling/dremeling out the wider flat end to fit over the clothes bar, so the originally open end would better wedge itself into the walls of the xB. Once I liked how they fit, epoxied them on to the bar permanently.
http://home.insightbb.com/%7Enpuzo/xB/shelf01.jpg
The stoppers fit perfect in the stock holes.
http://home.insightbb.com/%7Enpuzo/xB/shelf02.jpg
For now, in order to hold the extended rod in place I drilled 2 holes in each rod, and added 2 bolts, lock washers, and butterfly nuts.
http://home.insightbb.com/%7Enpuzo/xB/shelf03.jpg
They're rock solid once in place... forgive the junk in the trunk :P Used plastic electrical conduit clips also found at home depot to hold the board to the rods. Staggered the the back a little wider than the front and it also works as a hinge so the shelf can be easily flipped up for rear access.
http://home.insightbb.com/%7Enpuzo/xB/shelf04.jpg
With the auto/speaker/trunk carpet I purchased and spray glued to the board the gaps are minimal and the black goes with the interior nicely.
http://home.insightbb.com/%7Enpuzo/xB/shelf05.jpg
Smooth & solid support behind the back seat, looks stock, slight gap where it meets the hatch since there's a slight curve to the hatch I didn't realize when cutting the board.
http://home.insightbb.com/%7Enpuzo/xB/shelf06.jpg
Another look from the back seat.
http://home.insightbb.com/%7Enpuzo/xB/shelf07.jpg
Flipped down with the hatch open, stripes effect is from how the carpet was packaged and has since faded so not as noticeable. Sub hits harder too, but it'll be going under the passenger seat soon.
In all took me about an afternoon to make, mostly due to several home depot trips but like the result, it's very sturdy and really cleans up the look of the interior.
Hmm, now the more I look at it I could possibly do away with the front rod altogether if I could just have the stoppers or something else sticking out for the front to rest on, freeing up even more space....
dgHotLava
06-12-2011, 02:32 PM
great DIY there.
as for the thought of removing one of the bars and just letting it rest on something, i think that will cause a few issues.
it needs to be held in place from and back to keep it from rattling. it will bounce up with rough roads and good bass hits (even if under the pass seat.).
if you could put some kind of spring loaded catch on the shelf instead of a bar, i think you got it covered. making sure the board will not flex from strong springs..