projekt zeal86 (build thread)

[zeal86]

I will be fabricating some brackets to support the rear of the top panels. They will install using the OEM holes that were left unoccupied after I gutted out the back seats and all things related.

I haven't decided on the material to use just yet but I'm leaning towards aluminum. Planning on using a piano hinge to allow the back panel to open and close... I'll figure out the latching mechanism later... may even use velcro.

I think the hardest part will be making sure I get the bend right. If I make the top bottom panel in two parts, I may include a storage compartment. I'm also considering making the top bottom panel one long piece instead of two.

so far so good....

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projekt zeal86 build

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[zeal86]

Newest template cut from matte board...I cut it shorter than the last template because I plan on making the top panel a separate piece...I may cut the ledge down to 2.5" from 4".



Angled using a metal brake...







Looks like I'm going to go with Kydex 100 and ABS for the panels over aluminum. I had a piece of Kydex at work so I practiced a bend on it... it is only 3/32" thick but sturdy as hell. I will likely use Kydex for the bent sections and ABS for the flat panels. I will use a thicker ABS for the seat back panel.

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projekt zeal86 build

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[zeal86]

I ordered a sheet of Kydex T .093" x 24" x 48"... I'll use this sheet for the bent panels. The sheet cost $34.80 on Amazon.

I'm planning on ordering (2) .093 x "24"x 48" BLACK ABS sheets for the top panels and rise and (1) .177" x 24" x 48" ABS sheet for the seat back panel... I'm just waiting on some clarification about the shipping from the seller.

I can only do a little here and a little there throughout the week so this project will be a slow one.

When I'm done, I'll create a separate DIY write-up with all my templates and measurements plus step by step instructions. I'll try to make it as easy as possible for the next person who wants to attempt this modification...

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projekt zeal86 build

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[ichitaka05]

I'm interested to see how backseat delete panels goes.

[zeal86]

Ordered materials today minus the material/fabric I will use to upholster everything.

A little more work put in...

Template for rear panel support. I will use existing OEM bolt holes for mounting.



Straightened up the edge...



Traced out template on poster board... added a 1/4"...





Clamped together in order to (belt) sand down both panels even after using band saw to cut out shapes. Finished off details with a Dremel. Drilled mounting holes to 10mm using metric unibit.



Kydex 100 ready to be bent... I forgot my template or I would have completed this bracket tonight. I need it to reference the angle for the bends.




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projekt zeal86 build

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[zeal86]

Here is mock-up of what I have so far...



About to bend the rear supports on a metal break...



Complete...



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projekt zeal86 build

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[zeal86]

Made some improvements to my previous templates (LS) than made the (RS) templates from those. Right side top panel template made but not pictured.

Hope to be moving on to the next step tonight or tomorrow morning. I may combine the top panels into one panel. I think it will look like a cleaner install that way.



Creased on metal break...



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[olsonpg]

I love this. This guys not afraid to do new things !

If I'm able to do this without a metal bender I'd love to eventually take this on.

[zeal86]

Originally Posted by olsonpg

I love this. This guys not afraid to do new things !

If I'm able to do this without a metal bender I'd love to eventually take this on.

@olsonpg thanks for keeping up with my build... I plan on doing a thorough write-up once I complete the project. I definitely want to make this project less daunting for others to take on.

You can definitely pull this off without a metal bender or break... For example, you could use a different material... something like a stiff cardboard. You would be able to bend the cardboard over a table edge or something similar as long as it has a clean straight edge.

The cardboard if braced properly could handle some weight...It depends on if you really plan on using the space or if it is more for show. I'm using matte board from Hobby Lobby for my templates and I think that it is rigid enough to make this project a successful one. Especially once the matte board is upholstered... the chosen material/fabric will only add to the strength of the panels.

When my rear seat delete is complete... it will be able to support quite a bit of weight even though I don't plan on loading anything on top of it. I am planning on making a storage compartment for my specialty tools and a few other items though.

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projekt zeal86 build

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[Clipdat]

I admire your complete lack of laziness. I think your strict exercise regimen has something to do with how productive you are!

Once you finish your car please take a road trip out here to the bay area so we can visit some of the best driving roads!

[zeal86]

I test fit the templates I finished at work today... very minor adjustments and I will call it good! The rear supports turned out awesome... they definitely will add to the strength of the rear seat delete. I'll post pics in the morning...

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[olsonpg]

Originally Posted by zeal86

@olsonpg thanks for keeping up with my build... I plan on doing a thorough write-up once I complete the project. I definitely want to make this project less daunting for others to take on.

You can definitely pull this off without a metal bender or break... For example, you could use a different material... something like a stiff cardboard. You would be able to bend the cardboard over a table edge or something similar as long as it has a clean straight edge.

The cardboard if braced properly could handle some weight...It depends on if you really plan on using the space or if it is more for show. I'm using matte board from Hobby Lobby for my templates and I think that it is rigid enough to make this project a successful one. Especially once the matte board is upholstered... the chosen material/fabric will only add to the strength of the panels.

When my rear seat delete is complete... it will be able to support quite a bit of weight even though I don't plan on loading anything on top of it. I am planning on making a storage compartment for my specialty tools and a few other items though.

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projekt zeal86 build

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Definitely one of the most interesting build threads on this forum. Your originality knows no bounds!

I cant wait for the complete write up! I think i'll do as you say and use a stiffer cardboard material as my base and then throw 1 or two layers of carbon on top.

Possibly too, If you have extra Kydex when all is said and done maybe I could order a pair of those sexy brackets your making and leave you with a nice bit of profit.

Can't wait for updates.

[zeal86]

Some more progress... these panel templates are almost ready...



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[zeal86]

I had to adjust my rear support brackets upward on the insides and that left me little to no edge distance... so I adjusted my template and remade the supports.

I could have slotted the holes and that would have worked just fine but since I want these templates to be accessible to others... I wanted them to be as close to perfect fitment as possible.



This is the first template for the channel section of my seat delete project...made from pieced together poster board.





I should have my final templates for the lower portion of my seat delete project done tonight. I received my Kydex today so I may cut the angled panels tomorrow morning... I should receive my ABS sheets for the top panels and seat-back panel next week...





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