A Light Detour, part 2

Before installing all the interior carpeting I wanted to install a third brake light. I figure this will make things a bit safer by providing better warning to folks when braking. However, while doing all this, I realized I really wanted to get rid of the rear speakers (which were cheapo/ugly units) and all the assorted wiring. After all, I did not have a radio installed anymore, and they were useless.

So, while removing the rear speakers I noticed things might be a bit simpler if I removed the complete rear deck. Removing it was simple - there are three sheet metal screws that hold the piece in place. Undo these, pull the thing out, and it's all done.

The vinyl cover on the tray itself was in OK shape, but it had been cut to make way for the speakers. In all honesty, I think I won't be installing speakers any time soon, which means the holes in the original vinyl just won't work well for me. Which means I have to replace the vinyl fabric.

Sigh...

Vinyl fabric is not uncommon, but for a newbie, it seems hard to find - especially for specialied applications such as automotive stuff. At first sight, I though this would take me a few days (maybe a couple of week) just to find the proper materials to do this.

This is where google comes to the rescue: after a few hours, I had found PerfectFit Wholesalers in in Tukwila, WA (down the street from work.) These folks advertised a variety of vinyl fabrics and the such, and so, I paid them a visit in person.

Sure enough, they stocked some automotive-grade vinyl fabric closely similar to the old vinyl in the car. I ended up with some from this product line They also supplied a sheet of headliner foam which, although not an identical match for the deck padding, serves the purpose very well (and it will be hidden from view anyways.) They even sold paperboard, which I can use to replace the original paperboard tray, which is already in pretty sorry state. Total cost for materials was about $40.

I highly recommend this place for any sort of fabric/upholstery need for your automotive project.


I had to glue two sheets of fiberboard together, as they were too thin by themselves. This took about half a bottle of wood glue, and a couple of days for the glue to dry. I then used the original tray as a template, drew an outline, and trimmed the board down to shape with a circular knife and lots of patience.

Next I cut the headliner foam to shape, and glued it to the fiberboard tray with spray-on glue.



I also drilled three holes for the fastening screws. I used 1/8" diameter aluminum spacers to line the holes and keep the screws from tearing into the cardboard.










Next, I stretched the vinyl sheet around the bard and fastened it using 1/4" tacks and a good-ol' hammer. Nothing better than pounding car parts into shape...





I had to figure out a replacement for the old paper trim piece at the rear of the tray. It looked old and ragged, and would detract from the look of the fresh vinyl.



I fashioned a replacement trim piece out of a long 6" wide strip of vinyl wrapped around a 2" strip of headliner foam, and held together with spray-on glue.





I then tacked the trim piece onto the rear of the tray. I used longer thumb tacks for this.







The end product looked very nice. The vinyl trim piece looked better than the original cardboard trim piece (in my opinion.)







Here is a look at the tray installed (with the brake light - more on that next time.)







Next up - third brake light gets installed.