projekt zeal86 (build thread)

[CARBON10]

so killer man... I started reading your build at page 1 yesterday and just finished. Your attention to detail has given me ideas, and has made me backup and re-think what I'm doing with my own car.

[zeal86]

I didn't get around to doing much with the rear seat delete today... I just set the templates up to see what I would be up against tomorrow. What I found is that I have to raise the center of the panels as they drop about 1/2 as they approach dead center. I'm going to come up with a wedge spacer that I will probably run down the center. I will likely join both top panels... doing so will make it easier to raise the center with bias towards the rear.





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[zeal86]

I will create a dense foam spacer to fit the gap towards the rear.





Design change here... I was going to secure the channel differently... but in the process I noticed this was a easier option.

I'll extend out the top of the channel in my next template to line up with the OEM snaps.



Also, I will probably modify my rear supports once more... I'll raise them up a bit more...

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[zeal86]

I had planned to use alcantara but it is more expensive than I thought...I am also considering Bride fabric...

However, in the interest of saving money and still arriving at a desirable outcome, I wanted to source an OEM quality carpet that matches our interior in texture and color. I was hoping someone here has found such a product and is willing to share a link to the product page as well as a side by side comparison pic to the OEM carpet.

Thanks in advance!

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[ichitaka05]

Originally Posted by zeal86

I had planned to use alcantara but it is more expensive than I thought...I am also considering Bride fabric...

However, in the interest of saving money and still arriving at a desirable outcome, I wanted to source an OEM quality carpet that matches our interior in texture and color. I was hoping someone here has found such a product and is willing to share a link to the product page as well as a side by side comparison pic to the OEM carpet.

Not sure it helps, but didn't someone made some custom interior part? Like dashboard, knee pads, gauge trim & so on. I remember reading in "What did you do to your 86/BRZ today"

His material were bought all online (for decent price) & all looked OEM looking too.

Sorry couldn't be much of help.

[zeal86]

This should be the last version of the templates for the rear supports...



Top ledge will support the center channel and the lower ledge will support the top panels...





All rivets double countersunk... one bracket down one to go...





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projekt zeal86 build

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[zeal86]

I test fitted the latest version of my rear supports and they fit just right after I adjusted the angles of the top ledges downward.

Tonight I'm going to try and cut all the panels I've created templates for.

Next up will be getting the center channel template right... once that is complete I'll try and work out a way to hinge the seat back panel.

[zeal86]

Pics of newest supports installed...







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[zeal86]

I may or may not need to use this foam spacer but I cut it out anyway...





It is for the space pictured in the image below...



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[zeal86]

I'll probably still need to tweak the angles but at least the panels are cut from the Kydex T.



I cut the top panels from ABS and the material is not as rigid as the Kydex 100 of the same thickness.... hopefully once laid out it will suffice... if not, I'll have to brace it or order a thicker material.



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[zeal86]

Temp installed the mounting brackets to the angled panels... I made them out of .020" tclad aluminum. The aluminum should provide sufficient strength at the bracket location without the bulk.



This was practice piece I was working with in preparation for the final center channel panel...I believe I only have enough Kydex left for one shot at the panel... so I didn't want to mess up the material...



I had to beef up my foam spacer a bit...



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[weederr33]

Wow this is going along nicely. Can't wait to see the end product

[zeal86]

More progress pics...

The riveted bracket slides right behind the slit... I'll adhere a piece of OEM like carpet on top of the aluminum to conceal it ... This bracket adds additional strength to the panels...









I held the panels in place with tape so I can remove and rivet them...





The gap allows for fabric/material to fit snugly...



Center channel template fitment... will be velcro'd on two sides...







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[zeal86]

Partially riveted together... I used a hand squeezer for these rivets... I'll have to use a rivet gun for the rest...

***These panels could be cut out together from the template but I felt they would be easier to deal with as separate panels... plus, I would've had to buy a 48" x 96" sheet of Kydex or ABS.







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