projekt zeal86 (build thread)

[zeal86]

Tada...



On to bending the angles for the center channel...

This weekend I'll work out how I'm going to do the seat back panel... I have ideas but it depends on the strength of the center channel once it is secured...

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[ichitaka05]

Originally Posted by zeal86

This weekend I'll work out how I'm going to do the seat back panel... I have ideas but it depends on the strength of the center channel once it is secured...

This is the biggest part I'm interested on. Are you gonna make it foldable/easy to take it off or keeping it fully closed?

[zeal86]

Originally Posted by ichitaka05

This is the biggest part I'm interested on. Are you gonna make it foldable/easy to take it off or keeping it fully closed?

My original idea was to use a piano hinge on the top of the center channel so to make the seat back panel able to be opened and closed.

If I can pull that off... then I want to install a latching mechanism... I'm thinking of using a Quick-Latch mini for that... I won't know until after I have completed the center channel if a door panel could be supported.

I'm getting there though...

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[zeal86]

Originally Posted by ichitaka05

This is the biggest part I'm interested on. Are you gonna make it foldable/easy to take it off or keeping it fully closed?

oh ya... even if l don't end up making it a hinged panel door... I'm definitely going to make it removable... it won't be permanent...

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[zeal86]

Center channel angled... ready for a test fit!



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[zeal86]

Ran into a problem... I found there too much of a gap in one locale on both sides of my top panels... I did not notice until after my panels were riveted... All other positions are spot-on.

If I were planning this mod with no intentions of creating a write-up for others to follow, I would have just improvised... but instead I went ahead and ordered 2 more sheets of ABS to make the panels correct... and so I can have spot-on templates to share. I also bumped up the thickness of the panels from .093 to
.118

Here is the gap...



Added to the edge... I'll remove the panel and create a new template from it.



I also made a measuring mistake on my center channel... the bends were right but the length was short... I should have made one more template before cutting and bending the Kydex. Anyway, I ordered a new sheet of Kydex.

I pushed the channel over to the pictured side so the short side is not pictured. Also, for the seat back panel... I plan on following the contour as opposed to other designs I've seen on the net. I actually have not seen any rear seat deletes in person.



I feel confident I can pull off the hinged door... I feel the center channel will support a hinged door. In fact, I went ahead and ordered a 4 foot continuous (aka piano) hinge.

I'm looking into using a Quick-Latch mini to secure/release the panel door. I'm looking at placing them in the outer holes near the rear deck... it's where the OEM panel clips go. The inner two panel clips would stay.



Good thing is that while I wait on my materials... I could still move forward with my seat back panel template.

more to come...

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[zeal86]

I haven't had the chance to accomplish a whole lot today but I did get this done...

Seat Back Panel Template (v1)...



The folded poster board serves as a mock-up continuous hinge. The open width of the hinge I ordered is 2.5" as is the mock-up hinge. It will be on the trunk side of the panel so to keep the install clean and free of pops, rivets, hinges, etc...



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[zeal86]

Here is a crappy pic of the template in place...

**Keep in mind, the center channel and other panels are not secured yet... there will nice and clean seams in the end...




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[zeal86]

Some pics from the trunk side...



This is pretty much how the hinge will mount as well as how it will be viewed from inside the trunk... I plan to upholster the leaf of the hinge and spray paint the exposed knuckles flat black.





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[zeal86]

OK... so today I drilled out the rivets that pass through the top and angled panels. I have my new template so now I'm just waiting on the new ABS sheets to arrive to proceed.

I took the time to make templates for the proper angles of the angled panels. I did this by placing a panel upright on a piece of poster board then tracing the edges. I also created templates for the hole orientation of the top panels and supports for the angled panels.

Tomorrow I'll receive my hinge so I may tinker with the fitment and move forward with the seat back panel template.

more to come...

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[zeal86]

I received my new ABS panels today... I promptly took them to work traced my templates and cut them out.

I ordered thicker sheets this time because I felt the previous ones were a tad thin. I went up from .090 to .118...even though my digital calipers measured .123. Although it is not a big difference, it is definitely discernable as the panels feel a lot more rigid.

Previously I cut the panels out so that both had the textured sides facing up. You can't fit two panels on one sheet doing it that way. This time I made them fit on one sheet because it doesn't really matter that one smooth side will face up since the panels will be upholstered.



After cutting them out... I clamped them together so I could clean up the edges as one unit on a belt sander.



I'll receive my Kydex sheet tomorrow so hopefully I'll get around to modifying my previous template so I could get the center channel traced, cut, and bent. I hope to cut the seat back panel this weekend... if not, I'll work on it next week.

stay tuned...

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[zeal86]

I scuffed up these panels on both sides with 120 grit sandpaper so when I upholster them later the adhesive will stick better...





Here are the panels reassembled...





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[zeal86]

Ok..I'm pretty happy with how every is coming out... check it out.

I had to create a slight angle here to allow for the fabric to wrap later...





The center channel attaches to the OEM points using the OEM clips... the front side will attach to the top panels with velcro. I'll do that part after the fabric is upholstered. Also, there will be velcro on the underside of the center channel that hook to the top of my rear supports. It should be sturdy enough to support a hinged door.



Here is another wide view of every thing so far...



Started working on the hinge...I hope to have the door panel complete by Monday or Tuesday... then it will be waiting on fabric samples to arrive, making my choice, ordering, waiting, and then completing the build...

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[zeal86]

I'm trying to dial in my bends... crossing my fingers that the thick ABS sheet I ordered holds up to the bends... if not, I'll have to fork out some more cash for some Kydex...the .093" sheet in the picture cracked. My thick sheet is
.177".

Also in this pic, you could see the placement of my aluminum piano hinge.



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