|
Re: trunk board
Get a half sheet (4' x 4') of 1/4" 0r 5/16" Luan plywood from Lowes or Home Depot. This is a very fine dense grain without knots
Remove the plastic pieces at the bottom edge of the board by drilling through the rivets.
Lay your old trunk board on top of it and weight it down with a few bricks of pieces of cinder block to flatten it. Orient the plywood so the grain runs in the shortest direction (front to rear)
Trace around it and use a jig saw (either table or handheld sabre saw) Also cut out the hand holes and mark where the holes will be drilled to reattach the plastic clips. Drill the holes.
An easy way to cut perfect hand holes is to trace the rough outline. Use a hole saw to cut out the round ends of each hand hole and connect the two with a straight line)
Sand around all exposed edges to smooth the cuts.
Get some Thompson's Water Seal ans apply even coats to each side and the edges. I alternated coating both sides until I had 4 coats on each side. This stuff dries very quickly and adds firmness as well.
Reattach the two black plastic clips to the bottom edge, using large pop rivets and you are done.
I did this about 5 years ago when I first bought my polo and it has remained very sturdy and has not warped. The Water Seal keeps moisture and humidity from being absorbed.
If you want to make it EXTREMELY sturdy, cut a piece is 1" aluminum box channel and run it the width of the trunk board underneath (width of the tire well). Attach it from the top using long flat-head machine screws. They should be long enough to go through the board and through the box channel so that nuts can be attached from the bottom and the whole thing tightened down.
.
__________________
.
Subaru Ambassador
1996 Polo Green LSi #216 ..138,100 miles. ..SOLD
JFICX8659TH100216.....Date of Manufacture: November 16, 1995.....
Fuji Heavy Industries..Ōta North Plant....Ōta City,. Gunma Prefecture, Japan
In-Service Date: January 2, 1997
"The Pristine Green Polo Machine”
First Polo Green on the Network
First Clear front turn signals, JDM Alcyone hood emblem, rear panel, and BOXER engine cover on the Network (US) (2000)
First 5000K HID factory fog lights (2007)
First SVX JDM BBS wheels on a USDM SVX (2013)
HID lighting (5000K) for headlight and H3 fog lights, PIAA SuperExtreme 120W high beams, rebuilt EG33 longblock, Cometic head gaskets, Phase II flexplate, AMR aluminum radiator with custom silicone hoses, 160A high-output alternator in aluminum-ceramic coated case, new design alternator wiring upgrade v.4, rare factory headlight protectors, refinished JDM BBS mesh aluminum wheels and custom, polished billet aluminum new hex center caps, LED grille mod, R1 Concepts high-carbon cryo slotted rotors, Akebono ceramic pads, Goodridge S/S braided brake lines, Smallcar Stage 1 shift kit, ThermalTech aluminum/ceramic-coated valve covers, Energy Suspension urethane front & rear swaybar bushings, Bontrager22 rear swaybar with QS Components Chromoly Teflon/Kevlar endlinks, "$15.00/5 minute" suspension mod. Hella Supertone horns, Custom stainless steel exhaust system with 2" headpipes, Magnaflow cats, AeroTurbine AR25 resonator /AWD "Bullet" muffler.
R.I.P. 2010 Subaru Outback Limited 2.5 CVT...338,000 miles. Totaled by a 1,300 lb. COW March 4, 2016 
2014 Hyundai Avante Limited ...178,000 miles. Actually quieter and smoother than the Outback 
2007 Mazda Miata MX-5 PRHT...102,000 miles.
Plenty of parts, service and windshields. 
4th Registered Network member —2/21/2001
My NEW locker..I...My Email..I..Wikipedia/SVX .
.
Last edited by svxcess; 11-20-2008 at 06:59 PM.
|