Post #1
Just finished making my custom parcel shelf and this is how I did it, if anyonealcon has attached the following image:
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1999 GTi-6 (china blue)1999 Rallye (black)
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displaying posts 1 to 25 of 45
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 alcon
Senior User  Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
1999 Rallye (black) |
 Posted 25th Jan 2009 at 23:28
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #2
2. Take your jigsaw and cut the shelf to shape.alcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:35
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #3
3. With the shelf facing up the correct way, use the router and a alcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:35
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #4
4. Now turn the shelf upside down and round over the wiper motor cut out. All of this can be done with rough grit sandpaper if you don________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:36
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #5
5. Fit the shelf in the car to make sure it all fits ok, and close the tailgate to make sure there is no fouling. If there is or italcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:36
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #6
6. Next, pull the two plastic hinge pins from the original shelf and keep handy.alcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:37
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #7
7. Now take your piece of wood (I used a length of pine I had in my shed), cut it to the same length as the seat edge of the shelf and the clamp in place. Drill and screw it to the underside of the shelf as shown in the pics. Mark a line 30mm in from the edge and drill a 12mm hole centred on your line, in both ends of the shelf. The holes need to be at least the same depth as the length of the hinge pin. The holes should be drilled half in the MDF and half in the strip of would if youalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:37
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #8
-alcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:38
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #9
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:38
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #10
8. If youalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:39
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #11
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:39
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #12
9. Now decide where you want to mount your speakers and using the templates, draw on the underside of the shelf the positions, then cut them out with a jigsaw.alcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:39
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #13
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:39
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #14
10. Now is a good time to do final preparations to shelf before it gets covered. I used a small round-over bit to smooth all the hard edges but sandpaper will do the same job________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:40
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #15
11. Unscrew the strip of wood and stick a length of double sided tape to the TOP face (the top face is the side that gets screwed to the shelf if that makes sense). Peel off the backing and stick the edge of your cloth to it. Position the shelf upside down with the hinge edge closest to you. Screw the strip of wood back down which should now jam the cloth between the wooden strip and shelf. Wrap the cloth around the strip (conveniently covering the screws) and right round onto the top of the shelf (refer to pics to see what Ialcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:40
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #16
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:40
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #17
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:41
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #18
12. Reach for your stapler and start to tack it to the underside of the shelf. You need to pull the cloth taught as you do this to avoid any sags or wrinkles. Trim off any excess cloth and pay particular attention to trimming around the wiper motor cut outalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:41
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #19
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:41
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #20
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:42
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #21
13. You should now have a shelf that looks something like mine in the pic (or better!)________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:42
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #22
14. Now to cover the underside of the shelf. I used spray on adhesive which I bought in Maplins for a few quid as italcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:42
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #23
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:43
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #24
picalcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:44
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alcon
Senior User Location: Glasgow Registered: 19 Jan 2005 Posts: 936 Status: Offline |
Post #25
15. Gently tap/hammer the plastic hinge pins into the holes. I wrapped them with some leccy tape for a tight fit.alcon has attached the following image: ________________________________________ 1999 GTi-6 (china blue)1999 Rallye (black) |
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Posted 25th Jan 2009 at 23:44
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