DIY S13 Hatch Trunk Tray

[YellowStarS2000]

Since I bought a 240sx with a 5 lug conversion, there's no spare tire. There was no false floor covering the spare tire well, so cargo just sunk into the carpet. When I had an RSX, the trunk tray seemed really useful, so I decided to make my own.

Materials:
large piece of 1/8 inch plywood
Jigsaw
Liquid Nails adhesive in caulking tube
scissors
measuring tape
OEM hatch carpet
Vinyl rubber ribbed mat (in the flooring section of Home Depot)
Philips screwdriver
Flathead screwdriver
Permanent marker
2x hinges
wood screws

Step 1
Remove your carpet from the rear seats. You will need to use a Phillips screwdriver to remove the top screws and your fingernails or a flathead to remove the carpet clips.

Step 2
Place your carpet over the plywood. Trace the pattern of your carpet onto the plywood.
http://f.imagehost.org/0348/photo.jpg (http://f.imagehost.org/view/0348/photo)

Step 3
Place the plywood on an elevated surface. Use the jigsaw to cut the pattern you traced.
http://f.imagehost.org/0375/photo_2.jpg (http://f.imagehost.org/view/0375/photo_2)

Step 4
Cut your tray in half. This is so that your tray will actually fit into the hatch.

Step 5
Trace one of the halves onto the ribbed vinyl mat
http://f.imagehost.org/0263/photo_3.jpg (http://f.imagehost.org/view/0263/photo_3)

Step 6
Use the Liquid Nails adhesive and apply it to the edges to the wood and some in the middle.
http://f.imagehost.org/0678/photo_4.jpg (http://f.imagehost.org/view/0678/photo_4)

Step 7
Apply the ribbed mat to the plywood, flattening the adhesive.

Step 8
Wait for it to dry.

Step 9
Place a large piece of cardboard over the spare tire well (this is to prevent the split tray from sinking into the spare tire well)

Step 10
Use screws to attach the two pieces of the tray together with the hinges. The hinges will keep the two pieces of the tray together.

Step 11
Bend the tray at the hinge to allow the tray to fit into the hatch.

Step 12 (optional)
Cut the old carpet where the trunk tray ends

http://f.imagehost.org/0576/photo_5.jpg (http://f.imagehost.org/view/0576/photo_5)
http://f.imagehost.org/0968/photo_6.jpg (http://f.imagehost.org/view/0968/photo_6)

I'm not sure why mine didn't come flat, but I'm guessing it was because I didn't flatten the glue enough.

I'm enjoying the much better looking trunk tray as opposed to the 16 year old carpet in my hatch.

[OverBoost]

That's a pretty cool idea. How is it holding up so far? Pretty stable?

You could also cut out a door in the middle so you could access the spare tire well to hold smaller items.

Kudos to the DIY project!

[fuk240sx]

Nice! I think I'm gonna do this as well, I hate stuff just rolling around in the trunk.

[ixfxi]

wow..............................


you cut a piece of plywood and glued a piece of vinyl sheeting to it



the talent i am seeing here on zilvia is just endless, endless i tell you!

[ZX88]

why do you you need that in your trunk? areyou going to hold a dance party in the back of your 240?

[Nacho_240]

My 240 came with a tray. I like the carpet more.

Perhaps a better idea would be to use the spare tire area as a hidden compartment. Just add some carpeting or thick fabric and you have yourself a great hide-away spot for your JDM wheel. Also serves as a theft deterrent. Bonus!

[aoiken3]

it looks nice. props for doing it but its not really for me since it would add weight and look weird w/ it being there and the rest of my interior not there

[Fries]

I assume you put the carpet on top of that right?
I dont think this needed a thread on how to cut plywood haha.

[SoSideways]

This should have been in the "fabrication thread".

It's that worthy.

[irax]

wow..............................


you cut a piece of plywood and glued a piece of vinyl sheeting to it



the talent i am seeing here on zilvia is just endless, endless i tell you!



you know.... some times......


http://blog.synthesis.net/wp-content/uploads/2008/10/facepalm.jpg

even expensive cars come with plywood covers for the spare tire well in the trunk :mephfawk::mephfawk:


though, I would of liked to see him reuse the carpet that way it would look nicer but, I don't see anything wrong with this simple DIY. Not all of us are out to DIY fancy parts for money.

[YellowStarS2000]

:P I knew there would be some haters since I'm not posting how to do an RB swap with one hand while blindfolded

Anyways, my 240 isn't a race car or show queen, she's the daily driver and the largest car of the three me and the wife have by a long shot.
The carpet looked like utter crap, especially compared to how clean the rest of the car was. This makes cargo not slide around as much, more water resistant, and more durable for heavy things.

The carpet was cut to allow 2 inches of overlap so I could tuck just a bit of carpet under the tray.

The pieces weigh less than 5 pounds.

[BustedS13]

as soon as the whole car is fat-matted, i'll be doing something similar. mine's going to also be a rear seat delete and include some storage cubbies like an s30, and another storage door to access the spare tire well... probably cut a hole to fit a battery box in, as well.

lookin' good brah

[DDDsquad_s13panda]

looks kool but being it plywood then hitting metal, aint it making alot of rattling when your driving, unless you put some rubber stuff underneath like how the OEM once are. iono.. looks cool though, makes it look more cleaner.

though i dont have no interior in my trunk(coupe) cuz i got my 12's thumpin in there. lolx

[BustedS13]

looks kool but being it plywood then hitting metal, aint it making alot of rattling when your driving, unless you put some rubber stuff underneath like how the OEM once are. iono.. looks cool though, makes it look more cleaner.

though i dont have no interior in my trunk(coupe) cuz i got my 12's thumpin in there. lolx


.......................jesus