What started as a project to make a small pocket for my ice scraper so I don't have to dig for it in the trunk turned into a DIY project for a whole new trunk lid liner that adds some storage options to the BRZ.
First, I remove the stock liner. It's held in place with seven pop fasteners (which I'll re-use). The factory liner is made of some corrugated plastic covered with felt. It stays in place OK, but it's not stiff enough for what I'm about to do to it. Some earlier cars didn't come from the factory with this liner. You don't necessarily need it (it's getting replaced), but it helps to have a pattern.
I trace it out on some aluminum sheet, cut it to shape, and bend it in two places. I used a .050 inch thick sheet left over from another project, but I would go thinner if I did it again. Making the holes just a bit over size at this point will help with installation into the car later.
Next, I lay some nylon MOLLE webbing over the aluminum backing. MOLLE webbing is like a standard for securely attaching two fabric objects together. It's used by backpackers to create modular backpacks; police and military use it for making vests to carry ammunition, etc. You can make it yourself if you're handy with a sewing machine, but I bought an off-the-shelf sheet of it and cut it to size. As usual with nylon, all the cut ends have to be melted or they'll unravel.
There aren't many adhesives that stick to smooth aluminum but won't soak through and damage the nylon fabric. I use my go-to method for fastening fabric to metal: pop rivets; lots and lots of pop rivets. It helps to know where the new liner will contact the metal of the trunk lid; having a rivet sticking out there could scratch the paint or get in the way of installation. Taping over all the cut edges and sticking some foam rubber stickers on the backs of the rivets helps prevent scratches.
Mounting the completed (and much stiffer) liner on the trunk lid is more difficult than removing the old one, but the factory pop fasteners eventually snap into place. There are cutouts in the liner for some cables that connect to (I think) license plate bulbs and trunk release which need to be checked for clearance before putting it in place.
Now here's the fun part: outfitting the new trunk liner. I put in storage for the ice scraper, one for tools, and a quick-release first aid kit. Two more pouches are attached to the back of the trunk; I think I'll throw some tire chains in them or something. These pouches are available in backpacking or military surplus stores in various colors, or from searching the web for "MOLLE pouches". They're built to a standard, so they should all be compatible.
EDIT: passenger side dash panel now has the same treatment.
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