Planning to build Trunk Lid Storage

[Spektyr]

Update:

I have my mostly-finalized roadside kit figured out and stowed below the trunk floorboard. Everything fits nicely. I have a cargo organizer meant for keeping groceries or whatever from rolling around in the back of an SUV that collapses. The first aid kit and emergency lights fit in the end pockets of that with it collapsed, and it sort of wedges up between the inside of the trunk top on the driver's side and the floor of the trunk.

Roads today were garbage, so I couldn't get out to test whether it'll stay put like that, and that stuff isn't as accessible as I'd like so I'm still going to build my trunk lid storage - it'll be simple and I'll do a DIY for anyone that wants to do the same. But it seems like it should be a passable intermediate step.

[2020BRZtS]

I must be a bad road-citizen. I keep nothing in my trunk and only have the liner so my gas can doesn't slide around. The gas can is for the lawnmower and only put in the car a handful of times per season.

OP, I like your thought process and would love to see the finished result.

[soundman98]

Originally Posted by 2020BRZtS

I must be a bad road-citizen. I keep nothing in my trunk and only have the liner so my gas can doesn't slide around. The gas can is for the lawnmower and only put in the car a handful of times per season.

OP, I like your thought process and would love to see the finished result.

i really only do it for myself or sometimes immediate friends/family. but with my luck, it's better to be prepared for it because it's bound to happen..

my family is likely one of the only few that can say that we wore out a jack handle to the point that it needed to be re-welded...

[Caeser]

Have to be careful on weight so the trunk can still open when you press the button

[Spektyr]

Originally Posted by 2020BRZtS

I must be a bad road-citizen. I keep nothing in my trunk and only have the liner so my gas can doesn't slide around. The gas can is for the lawnmower and only put in the car a handful of times per season.

OP, I like your thought process and would love to see the finished result.

I'll definitely post some pictures - I'm planning to do a full How To write up of how I do it. I'm having some issues sourcing the parts I want to use, so it may take a little while for me to get it done properly.

My design challenge has several points:

• It should look nice
• It should function properly
• It should not be cost-prohibitive
• It should not be skill-prohibitive

This is all somewhat subjective, but in particular I'm looking to build it in a way that is as "off the shelf" as possible so that people of varying skillsets and tool collections can reasonably build one themselves.

[Spektyr]

Quick update: Ikea decided to go ahead and let me order ALL the stuff instead of merely half of it for delivery.

It'll arrive while I'm at ISC West, and then I'll get to work on modifying it for the car once I'm back.

So maybe a couple weeks and I'll have something to show?

[Spektyr]

It's begun.

https://photos.app.goo.gl/9KEAxH6ADUuDayux9

Going to do a carboard template, get that how I like it then cut it in half down the centerline so I can get it perfectly symmetrical. Cut that out of the white Ikea pegboard and mount it with some kind of standoff.

Things to resolve:
How to attach standoff to trunk lid liner - shouldn't scratch paint on trunk lid.
How to attach pegboard to standoffs. Unless I do big cutouts for the pop clips that hold the liner to the trunk lid I have to be able to install the liner, then the pegboard to the standoffs since it will cover the pop clips. That should also be aesthetically pleasing since it will be visible.

Not difficult things to solve, of course, just walking away from it to take some time to think (and maybe get some good suggestions here).

EDIT: Oh, and I'm kicking around the idea of doing a close color-match paintjob on the white plastic pegboard. Any idea if there's a decent match for Trueno blue in a rattle can? Otherwise I'll just go with something neutral or possibly an accent color. Hell, Caution Orange might not be bad - if the trunk's up it's extra "hey, don't hit this car".

[soundman98]

Originally Posted by Spektyr

Things to resolve:
How to attach standoff to trunk lid liner - shouldn't scratch paint on trunk lid.

honestly, go take a long trip through your local home improvement store-- don't limit yourself to any specific department. i find lots of my idea's there--the last project, i wanted to add a spare tire to a power wheels jeep. the inner diameter of the wheel i was using didn't fit any sort of standard tubing size, 3/8" rod was a 1/4" loose, 1/2" rod was about 1/16" oversized. after scouring hardware, plumbing, shelving, and hvac, ended up finding a steel window shade rod that was the perfect diameter...

https://i.imgur.com/xQyhzod.jpg


anyways, my first idea is t-nuts with the spikes ground off. they're likely going to be the easiest method i know of. disadvantage is that they're metal. that can be worked around by backing them up with duct tape, electrical tape, or my personal favorite, old towel. 6-32 t-nuts should be more than enough, could step up to 8-32 as well.

second idea is jb weld/epoxy some nuts/all-thread, but the flexibility of the trunk liner means the rigid epoxy is likely to break loose over time.

Originally Posted by Spektyr

How to attach pegboard to standoffs. Unless I do big cutouts for the pop clips that hold the liner to the trunk lid I have to be able to install the liner, then the pegboard to the standoffs since it will cover the pop clips. That should also be aesthetically pleasing since it will be visible.

if the t-nuts are taped in place to the trunk liner, you could install the peg board after mounting the trunk liner. that would solve the 2nd problem. the 1st problem would be spacing the peg board off enough to make use of the peg holes.

they make white nylon spacers in the hardware isle that work for this. but personally, i like using 1/4-20 nuts for the purpose. they're smaller diameter, more rigid than the plastic, i find the silver a little less eye-catching than the white nylon, and in my specific case, the stores near me usually only stock 3-4 spacers of any given size, while 1/4-20 nuts are stocked by the crate, so any quantity needed over 4 is much easier to work with the nuts over the spacers.

Originally Posted by Spektyr

EDIT: Oh, and I'm kicking around the idea of doing a close color-match paintjob on the white plastic pegboard. Any idea if there's a decent match for Trueno blue in a rattle can? Otherwise I'll just go with something neutral or possibly an accent color. Hell, Caution Orange might not be bad - if the trunk's up it's extra "hey, don't hit this car".

can usually get pretty close a lot of times with the off-the-shelf variations. there's also a number of places on ebay and amazon that will custom-mix aerosol cans of any color you want, just need a paint code.

[timurrrr]

Here's a cargo net I'd use for a small first aid kit to keep it easily accessible in the trunk, whether it's empty or full of other stuff.
I used a similar cargo net in my 2017 BRZ for a while and loved it.



Toyota part number PT347-18220, the instructions say it's for 2022+ 86 (no "GR", lol)
and installation is super easy. $45 from a local Toyota dealer.

[Spektyr]

Yes, I remember this exact conversation from page 1.

[timurrrr]

Now with the part number and photos!
This is also a data point for other readers, not just you.

[Spektyr]

Another quick update:

I'll do all the pictures at some point, actually posting pictures on the forum is annoying so I'm just going to do it once. (I've been spoiled by modern tech where you can just CTRL-V whatever you want, wherever you want.)

So what I did was take the liner off the trunk lid and laid it out on a piece of cardboard. Traced out the bottom of the liner (up to where it folds) and cut that out. Trimmed and made sure it was exactly where/how I wanted it to be and then drew a center line vertically in the middle. It's easy to think you have something symmetrical, but nothing beats using the same side on both sides.

Then I took that and bolted it to the Ikea pegboard which - importantly - has slots instead of pegs. Bolts went through the centerline of the pattern. Trace one side onto the pegboard, flip the pattern and re-bolt it, then trace the other side. Result: perfect symmetry.

Then using a hand jigsaw I cut that out (ruining the symmetry but it's close enough). Chamfer the edges, check the fit on the liner, and then it went for a rattle-can coat of blue that's not far off from the Trueno on the car.

So that's where we sit now - letting that coat dry and then I'll evaluate additional coats.

Important note: the Ikea pegboard looks and feels like plastic, but it's high-density board of some flavor - the cut edges look like hardboard or compressed cardboard. Sturdy enough, but it's not plastic as I originally thought. The big drawback is if you can't really skip painting it without leaving brown edges.

As far as stand-offs go, I figured that out. I want to bolt them to the liner, install the liner on the car, and then bolt the pegboard to the liner (this way I can cover up the plastic fasteners and still be able to take everything apart and reassemble with ease.) My concern was that I needed the standoffs and the bolts on the back of the liner to not turn when I tighten the pegboard bolts down. Enter the slotted holes of the Ikea pegboard.

I quickly mocked-up a standoff in Tinkercad and printed a prototype. It fit perfectly. 20mm cylinder 15mm tall. To that add an extruded slot on the top 5mm tall, 5mm wide, 15 mm long, with 5mm radius on the corners (rounding them completely). Center all that and then bore a hole down through with a diameter that will thread nicely onto your bolts (I went with 3.85mm since I'm using M4 flat head bolts with washers.)

I have 1" wide strips of adhesive felt to apply over the bolt heads on the back side of the liner to protect the paint.

I will install the standoffs on the pegboard (they friction fit) where I want them, line everything up the way I want on the liner, and use a punch to mark where the holes line up. Then I can push the bolts through with washers to improve their grab and tighten the spacers down with the tabs out. Apply the felt and then install the liner on the car.

At that point the pegboard can be slotted onto the standoffs and bolts/washers installed to hold it in place.

Once I'm done with paint it'll go together quickly, I'll get the final load of pictures taken, and upload link them all at once.

[Spektyr]

It's done:

https://www.instructables.com/Trunk-Lid-Organizer/

[soundman98]

still pending. making sure you didn't sneak any child porn or smut films into your pictures.