How To: Wood Backed Trunk Liner (Solid Base Trunk) - Chevy Cobalt Forum / Cobalt Reviews / Cobalt SS / Cobalt Parts
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post #1 of 9 (permalink) Old 04-03-2012, 03:52 PM Thread Starter
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How To: Wood Backed Trunk Liner (Solid Base Trunk)

The other how-to on this doesnt have pics so...


Estimated Install Time:
About 30 minutes

Tools:
piece of wood
stock trunk liner inlay
pencil
jig saw
spray adhesive (or whatever you want to use)
10 screws and screwdriver
knife

Step 1:
Remove stock inlay w/ cardboard backing. This is now your template.


Step 1b (optional):
You may want to pull the power wires up and reroute them around the spare tire. Not mandatory, but might keep the base more balanced for the end product.
You can also remove the other bits of cardboard and carpet filler if you wish.
I chose to keep the carpet filler to add some cushioning in hopes that it would compress a bit and keep it more balanced...this turned out to work pretty well.


Step 2:
Flip the stock carpet upside down on the wood of your choice.
Trace the outline of it, cut it out with a jig saw.
peel off cardboard backing and throw it at someone



Step 3:
Cut this piece down the middle, otherwise its not going to fit in the trunk.
This also makes it MUCH easier to access the battery while still maintaining a solid base.
Test the fit



Step 4:
Cut a strip about 3-4 inches wide and screw this to the bottom of the left half with 1-2 inches overhang.
This will allow the right half to slide out to access the battery, and keep the pieces rigid.
Test fit the pieces again

*Not the piece that hangs off in the middle of the trunk*


Step 4b (optional):
Because I have power wire running beside the batter to my amps, I also notched a 3x3" piece for the back corners to give a little extra height. These corners are the furthest left and right most parts of the wood by the bumper. It might be necessary to do this even if you dont have any wires running out there just to give it more stability.


Step 5:
Put one of the halves of the wood on the carpet, and cut the carpet in half.



Step 4:
Glue both pieces of carpet onto your cut pieces of wood.



Step 6:
Install the left piece


Step 7:
Install the right piece

Last edited by acoutu; 04-03-2012 at 03:54 PM.
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post #2 of 9 (permalink) Old 04-03-2012, 03:54 PM
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Nice! I just did this over the weekend but cut it a tad bigger than the stock cardboard and glued it all down so I wouldn't have to pull out multiple pieces. This was one of the ideas I was throwing around though!
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post #3 of 9 (permalink) Old 04-03-2012, 08:10 PM
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doing this same thing and then i am making a mdf wall in trunk with 2 kicker solo barric l7's oh yeah. tired of screwing around with the system i am gonna do it right and keep it that way

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post #4 of 9 (permalink) Old 04-04-2012, 04:06 AM
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I've been wanting to do this for awhile, just been to busy/lazy lol

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post #5 of 9 (permalink) Old 04-04-2012, 05:09 AM
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What thickness plywood did you use? 1/4"?



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post #6 of 9 (permalink) Old 04-04-2012, 09:44 AM
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I used 1/4 and I think I could put at least three bodies on there before it started to flex!!! haha just kidding.

The reason I used the stock insert as my template is because the trunk actually recesses to keep the entire trunk flat. With 1/4 inch it barely sticks up due to the recess.
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post #7 of 9 (permalink) Old 04-04-2012, 11:10 AM Thread Starter
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Quote:
Originally Posted by dondiego View Post
What thickness plywood did you use? 1/4"?
I used 1/2", I have a lot of tools and they literally cracked and crumpled the OEM cardboard.
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post #8 of 9 (permalink) Old 04-04-2012, 11:28 AM
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^I did mine becuase I put 200lbs of sand in the back and it just caved!
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post #9 of 9 (permalink) Old 04-04-2012, 11:42 AM
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Would that hold my mother-in-law??? She says she's not heavy, that it's just an optical illusion.

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Last edited by Coby7; 04-04-2012 at 11:46 AM.
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