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DIY: Rear Cargo Hatch Cover

Old 17-Mar-2008, 10:51 AM
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Post DIY: Rear Cargo Hatch Cover

First off, this isnt me, but a great diy if you ask me.




Yesterday I decided to make my own rear hatch cargo cover. I have a sub and don't want to advertise it, and after not finding an oem one for a decent price, I thought why not? So here's a bunch of pictures and instructions on how you can make your very own...

First you need to go to pick and pull and find some rear hatch cover brackets from any Honda really, I got mine from an Acura integra. I just ripped the brackets that snap into the slots off of the original Integra cargo cover, and used those.

Then you need to buy some hardboard from a local hardware store. A quarter sheet, 1'x4' is enough. I bought the thicker stuff so it would not bow or bend. Then you also need some black felt to cover it with. 1.2 meters worked for me, it's super wide, so you just need the 1.2 meter length, and the brackets like mentioned before. (Ignore that metal tube, I was going to use it as a mid support but it wasn't strong enough.)

Then you need to cut the board to the right length, it was 45 3/8" for my hatch. After that you can mark out the rough curve and the width and cut it out with a jigsaw. Do one side of the curve first, then make a carboard stencil to do the other side becuase both sides are semetrical.

Then flip the stencil over and cut the other side

Then you will need to cut the right grooves along the rear of the hatch. We did one side rough and made sure it fit, then made another stencil and did the other side.

Then once you have it fully cut it should look something like this



Once you've test fit the cover, make sure it's perfect. It might take a bit of planing, or electrical sanding to get the lines just like you want them. The rear hatch bottom part has a slant at the top, you want the cover to sort of rest halfway on that, as well as the grooved out lines on the side of the hatch, near the windows. You'll see when you take a detailed look at your car. So now that you've test fit it and are happy, you can put in the clips you got like so



Then put the brackets on the other side, and lay down your cover on top of them. Now you are ready to mark where the brackets fall in place on the underside of your cover.



Then once you have them lightly marked, you can make the line more bold so you know exactly where they fall in place. Now that you have your lines bolded, you can then hotglue the brackets in place on the underside of the hardboard. Make sure you roughly sand up the brackets so the glue can adhere best to it.


Now that you have all your brackets glued on, you can put the felt on it. Flip the board upside down so your top piece of felt is totally solid with no lines or cuts. Then go around 3 sides of the board and fold the felt over about 1 inch or so, stretching it evenly, and hot glueing it in sections of 5-6 inches. Don't press too hard when you glue it becuase the heat of the glue can penetrate the felt. A light press will work fine and will keep it on there good. I cut mine nice and neat so all the folds were similar. Here's your almost finished cover...


Then stretch the long piece over the bottom of the cover. Basically you're going to make the seem around the edges, just covering what you originally pulled over. You also have to cut around the brackets. I glued them to the board first becuase of strength, I didn't think they would adhere too well to the felt if you pre-upolstered it. It's not going to be perfect, but it's the underside, so it doesn't really matter.




Look at that good lookin' kid

Finally, here's some pictures of the cargo cover installed in the car.







Sorry, some pictures are dark, but I did this in the evening. This was my first write up so sorry if some parts are confusing or misleading. Overall it's a pretty easy project, cheap and serves a pretty decent purpose if you don't want to advertise what you are storing in your easily broken into truck. It's not super strong, so I wouldn't put anything heavy on top of it, but it looks pretty.
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Old 17-Mar-2008, 01:40 PM
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wicked writeup!!
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Old 17-Mar-2008, 03:58 PM
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good looking kid............?
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Old 18-Mar-2008, 10:17 AM
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it aint me lol
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Old 18-Mar-2008, 11:34 AM
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no lol i know just commenting....lol
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Old 18-Mar-2008, 05:12 PM
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good job!
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Old 18-Mar-2008, 09:57 PM
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it looks like that cargo cover should be a surf board...haha sorry to keep knockin on the kid...
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Old 19-Mar-2008, 08:37 AM
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Nice write up man!
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Old 21-Mar-2008, 02:03 PM
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That writeup is off of Clubcivic, The username of the person is AlexM. He did a good job.
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Old 21-Mar-2008, 03:05 PM
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yeah it is, any problem with that lol jk
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Old 21-Mar-2008, 03:41 PM
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looks good nice job
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Old 03-Apr-2008, 10:20 AM
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Good write up buddy. Pat your'self on the back for a good job!!
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Old 03-Apr-2008, 10:47 AM
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great write up .. one thing .. can it be folded ?? like the ek's ? private cover ?
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Old 03-Apr-2008, 12:00 PM
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it looks like a one piece ... so no folding ... but i think you can technically make it fold ... cut the cardboard where you want the fold and duct tape the 2 parts together so that the duct tape becomes like a hinge ...
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Old 03-Apr-2008, 12:10 PM
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To make it fold just to to Home depot and grab some hinges, cut the cover where you want it to fold and screw the hinges on. Done, now you have a folding cover
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Old 01-Jun-2009, 11:37 PM
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Anyone try this yet? Ive got my cardboard temp cut out and ready to go. Im getting the hardboard tomorrow and Ive already got the fabric picked out at fabricland, I just have to swing by a junkyard and get clips.

I guess I just want to know if anyones done this and if there having any type of problems with it?
Thanks
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Old 11-Mar-2010, 09:42 PM
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nicely done.
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Old 19-Apr-2010, 11:18 PM
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Awesome write-up!
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Old 20-Jun-2010, 01:19 AM
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i wonder how the glued **** held
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Old 20-Jun-2010, 01:35 AM
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ive done this. it work alright but if you can get your hands on a oem cargo cover its better just to cop it.
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