How to make your own DIY kickpanels...

Started by JiMR2, June 22, 2010, 15:06

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JiMR2

Hey all,

Following on from the following post;  m http://www.mr2roc.org/phpBB3/viewtopic.php?f=8&t=29590 m  I'm happy to say that after some messing around waiting for my stereo trim I have now knocked up a write up to include a rough template.

Here was my car after fitting a new double din HU, neons in the footwell, aerial switch and an active sub...

End result = lots of cables all over the place despite trying to manage them with cable ties;



So heres what I knocked up;



And here is how I did it...

You need;

Cereal box (empty) x 2 OR templates below
Some acoustic carpet from Ebay 1m x 1m (I used 1m x 2m and had LOADS left)
Adhesive spray "stuff"
A standard size sheet of plywood, 3mm thickness
Jigsaw / Band saw
An L shaped bracket (I just cut the end off a bracket i had laying about)
1 x screw
Optional:- rocker switch for aerial on/off  

1) Remove the side trims on the stereo centre console; this is covered here;  m http://www.mr2roc.org/phpBB3/viewtopic.php?f=47&t=12583 m  

Once the sides are off, clear out the footwells - including the mats so you've a nice empty space to work in.

2) I used some cardboard (unfolded cereal box) and placed it in the footwell to make up a rough template of the shape/size that i wanted to cover.

Luckily enough, when I took the stereo back out to fit the trim, I took an outline of the carpetted kickboards and have uploaded the template here;

 m http://www.mr2roc.org/phpBB3/images/art ... kboard.pdf m
 m http://www.mr2roc.org/phpBB3/images/art ... kboard.pdf m

Print these on A4 paper (3 sheets) and then stick them together, it should be fairly straight forward. I wasnt sure how else to get the templates up... bare in mind these are the carpetted ones so maybe knock 5mm off all round when cutting your shape... It gives an idea of the shape/size though...

3) Using your drawn template or the printed ones from above, keep trimming/offering up the kickboard to the area you want it to fit until your relatively happy.  

For the drivers you want to wedge it between the left hand side of the footrest and have it so that the other end is touching the metal frame of the centre stereo area but it should sit snugly behind the back of the plastic trim part (I haven't a pic of this but once you knock up the wood you'll see exactly what i mean); see below picture of passengers side for an idea;



For the passengers side lifes a bit easier. As you will see from the template it has a nice curved base which is much more forgiving. Again, follow the template and you should be ok. No wedging is required but we'll get back to that.

4) Once you've got your neat and tidy, fitting kick panels, your ready to carpet. Lay your panels on the carpet and draw a rough outline of the shape, 1" from the actual wood. Then cut the carpet out and grab your spray adhesive. Do this outdoors as its a bit whiffy. Spray on the back of the carpet and on the CORRECT side of the board.

So you should end up with;

Passengers side;


Drivers side;


And carpetted;





To put rocker switches in IF you want to is straight forward - just buzz a hole through the wood before carpetting and make sure the rocker fits tightly. Then carpet, cut the carpet and poke through. Then place the rocker. Simples!

The drivers side should fit snuggly indeed.

The passenger side needs one last mod to ensure a nice, tight fit. Place your kickboard into position, with the pillar trim in place and then screw the bracket into position in the heater duct for your feet so that it supports the back end of the panel, I just used a self taper;





It may be hard work trying to get the pillar trims back on at first but dont worry, as long as they're not in the way of the back of the trim you'll be fine, just stay patient!  s;) ;) s;)  Just pop it all back together and hey presto!





Simples!
AKA Cinnamon Jim

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